Apparatus and method for monitoring conveyor systems

ABSTRACT

In one aspect, an apparatus is provided for a conveyor belt system. The apparatus includes a conveyor belt cleaner having an elongate support and a pair of mounts configured to position the elongate support to extend across a conveyor belt. The apparatus includes a cleaner blade configured to be operatively mounted to the elongate support and engage a conveyor belt. The apparatus further includes a sensor configured to detect at least one characteristic of the elongate support as the elongate support vibrates during conveyor belt operation. A processor of the apparatus is configured to use the at least one characteristic of the elongate support to predict at least one property of the cleaner blade.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of Unites States application Ser. No.16/229,946, filed Dec. 21, 2018, which claims benefit under 35 U.S.C. §119(e) to U.S. Provisional Application No. 62/610,015, filed Dec. 22,2017, and U.S. Provisional Application No. 62/733,367, filed Sep. 19,2018, which are hereby incorporated by reference herein in theirentireties.

FIELD

This disclosure relates to conveyor systems and, more specifically, tomonitoring components of a conveyor system.

BACKGROUND

Conveyor systems are utilized to transport materials or objects from oneposition to another. One type of conveyor system is a conveyor beltsystem which may include a series of rollers and a conveyor beltarranged to travel thereover in a downstream belt travel direction andpath. Rollers include both drive rollers or pulleys and idler rollers.Drive rollers are connected to a power source, such as a drive motor,which rotates the drive roller and the drive roller in turn acts uponthe conveyor belt. For example, a conveyor system may include a headroller, a driven tail roller, idler rollers intermediate the head andtail rollers, and a conveyor belt forming a loop around the rollers. Theconveyor belt has a top run generally above the idler rollers and areturn run generally below the idler rollers. The driven tail rollerengages the conveyor belt and drives the conveyor belt top run in alongitudinal, downstream belt travel direction and path. The idlerrollers contact and the bottom surface of the top run of the conveyorbelt to support the weight of the material carried by the top surface ofthe top run of the conveyor belt. The idler rollers spin in response tothe frictional engagement with the bottom surface of the top run of theconveyor belt and may include roller bearings to spin easily.

Conveyor belts may meander or mistrack laterally toward one side or theother of the rollers due to reasons such as uneven loads carried by thebelt. Conveyor systems may include conveyor belt tracking devices thatrespond to belt mistracking by redirecting the belt back to the correcttravel path of the belt which is substantially centered on the conveyorrollers. Some tracking devices comprise at least one roller along whichthe belt travels. The at least one roller is pivotal in response to beltmistracking so that the pivotal roller acts to redirect the conveyorbelt back toward its correct travel path. Exemplary tracking devices aredescribed in U.S. Pat. No. 8,556,068 and U.S. Patent Application Pub.No. 2016/0264358, which are both hereby incorporated by reference hereinin their entireties.

Conveyor belt systems may be used to transport different conveyedmaterials such as coal or aggregate. During use, residue from theconveyed material can build up on a conveyor belt. The residue mayinclude small particles and/or liquids that stick to the belt such thatthe residue remains in contact with the conveyor belt surface after therest of the conveyed material is discharged from the belt. Conveyor beltcleaners may be used to remove this residue and debris. A conveyor beltcleaner may include one or more scraper blades mounted to an elongatedsupport member, such as a support pole, extending laterally across thebelt with the scraper blades biased into engagement with the surface ofthe conveyor belt. The scraper blade scrapes away the residue as theconveyor belt moves along the travel path. The ends of the pole extendbeyond the lateral sides of the belt and are mounted to the structuresupporting the conveyor belt via resilient mounting mechanisms that biasthe pole and the scraper blade mounted thereto toward the belt so thescraper blades are in resilient engagement therewith. The resilientengagement permits scraper blades to deflect out of the way ofirregularities in the conveyor belt such as a splice of a conveyor belt.The splice of the conveyor belt may include mechanical fasteners securedto ends of the conveyor belt that are intermeshed and joined together bya hinge pin. The splice may also include metallic fasteners that havefastener plates, rivets, and/or staples that extend above an outersurface of the belt and contact the scraper blades engaged with the beltwith each rotation of the conveyor belt. Another type of conveyor beltsplice is a solid plate fastener that joins the ends of the conveyorbelt and extends across the conveyor belt. The solid plate fastener mayalso extend upwardly from the outer surface of the conveyor belt andimpact the scraper blades engaged with the conveyor belt. The resilientengagement of the conveyor belt cleaner allows the scraper blades todeflect out of the way of the splice without the scraper blades damagingthe mechanical fasteners.

Some conveyor belt systems are loaded by discharging the material to beconveyed onto the belt. For example, a conveyor system for conveyingcoal or aggregate includes an impact area or loading zone along the pathof the conveyor belt in which coal or aggregate is discharged onto theconveyor belt. The discharging may involve the coal or aggregatedropping several feet or more before landing on the top surface of thetop run of the conveyor belt. Impact beds support the bottom surface ofthe top run of the conveyor belt along these loading zones to absorbsome of the impact from the material discharged thereon. Impact bedsinclude platforms and/or bars that contact the top run bottom surfacealong the loading zone. The platforms and/or bars typically are formedof elastomeric material which allows the platforms and/or bars toresiliently deform when impacted. Impact beds may include raised sidesso as to support the belt in a generally U-shaped configuration alongthe loading zone. This reduces spillage of material.

The components of a conveyor belt system may wear down over time orbreak down due to one or more components of the system breaking. Forexample, the scraper blades of a conveyor belt cleaner will wear downover time and may have less than the desired engagement with theconveyor belt. Current monitoring methods for scraper blades and idlerrollers involves directly monitoring the condition of the scraper bladeby embedding wires or sensors into the blade or idler roller.

SUMMARY

In accordance with one aspect of the present disclosure, an apparatus isprovided that includes a conveyor belt system comprising a conveyor beltcleaner. The conveyor belt cleaner has an elongate support and a pair ofmounts configured to position the elongate support to extend across aconveyor belt. The conveyor belt cleaner includes a cleaner bladeconfigured to be operatively mounted to the elongate support and engagethe conveyor belt. The apparatus further includes a sensor configured todetect at least one characteristic of the elongate support as theelongate support vibrates during conveyor belt operation. A processor ofthe apparatus is configured to use the at least one characteristic ofthe elongate support to predict at least one property of the conveyorbelt system. In this manner, at least one property of a component of theconveyor belt system may be predicted by sensing vibrations of theelongate support rather than the component directly. This protects thesensor while providing desired information about the conveyor beltsystem.

In one embodiment, the apparatus includes a housing configured to bemounted to the elongate support and the sensor is in the housing. Thehousing permits the sensor to be mounted to an elongate support of anexisting conveyor belt cleaner rather than requiring replacement of theconveyor belt cleaner. Further, because the housing is configured to bemounted to the elongate support, existing cleaner blades may continue tobe used which simplifies installation.

In one embodiment, the elongate support includes a pair of opposite endsand an axis extending therebetween. The sensor is at one of the ends ofthe elongate support axially outward from one of the mounts. Thematerial carried by the conveyor belt is carried along a path generallybetween the mounts of the conveyor belt cleaner. Because the sensor isaxially outward from one of the mounts, the sensor is outside of thepath of the material being handled by the conveyor belt. This protectsthe sensor by reducing the exposure of the sensor to particles such asdust and small rocks that may fall off of the conveyor belt. In someembodiments, the apparatus includes a communication interface configuredto communicate, via a wireless network, the at least one characteristicto a remote computer including the processor. The sensor being axiallyoutward from the one mount may reduce electromagnetic interference fromthe support structure of the conveyor belt system.

In accordance with another aspect of the present disclosure, a method isprovided for monitoring a conveyor belt system. The conveyor belt systemincludes a conveyor belt and a conveyor belt cleaner having a cleanerblade configured to engage a conveyor belt. The conveyor belt cleanerincludes an elongate support and a pair of mounts configured to positionthe elongate support to extend across the conveyor belt. The methodincludes detecting, using a sensor associated with the elongate support,at least one characteristic of the elongate support as the elongatesupport vibrates during operation of the conveyor belt. The methodfurther includes using the at least one characteristic of the elongatesupport to predict at least one property of the conveyor belt system. Inthis manner, the at least one property of a component of the conveyorbelt system may be predicted without having to measure the property atthe component itself. Because some components of the conveyor beltsystem such as cleaner blades wear down and are periodically replaced,the method permits continued monitoring of the conveyor belt systemdespite replacement of the cleaner blades or other components of theconveyor belt system that may wear out over time.

The subject disclosure also provides an apparatus for monitoring aconveyor belt cleaner. The apparatus includes a housing, a mountingportion of the housing configured to be secured to a support pole of aconveyor belt cleaner, and a sensor in the housing configured to detectat least one characteristic of the support pole as the support polevibrates during operation of the conveyor belt. Conveyor belt cleanersupport poles are somewhat standardized in the industry and, because themounting portion is configured to be secured to a support pole, theapparatus may be secured to different models of conveyor belt cleanersfrom a manufacturer or conveyor belt cleaners of differentmanufacturers. This improves the ease with which a user may install orservice the apparatus on a conveyor belt cleaner.

The apparatus includes communication circuitry in the housing configuredto communicate with a remote computer via a network. The apparatusfurther includes a processor in the housing that is operably coupled tothe sensor and the communication circuitry. The processor is configuredto cause the communication circuitry to communicate data associated withthe at least one characteristic of the support pole to the remotecomputer. The communicated data may be used by the remote computer tomonitor the conveyor belt cleaner, the conveyor belt, or a combinationthereof. In one embodiment, the remote computer receives the data fromthe communication circuitry and uses the data to predict at least oneproperty of the conveyor belt cleaner, the conveyor belt, or acombination thereof

In accordance with another aspect, an apparatus is provided forconnecting a sensor module to a support pole of a conveyor belt cleaner.The apparatus includes a body having an outer surface for receiving asensor module and a mounting portion sized to fit in an opening of asupport pole and extend along an inner surface of the support pole. Theapparatus further includes an actuator operatively coupled to themounting portion and movable to cause the mounting portion to engage theinner surface of the support pole. With the mounting portion secured tothe support pole, the body of the apparatus vibrates with the supportpole during operation of the conveyor belt. The sensor module may senseat least one characteristic of the body as the body vibrates with thesupport pole during conveyor belt operation. In this manner, the atleast one characteristic of the body may be used to determine at leastone property of the associated conveyor belt system when it is notpractical to mount the sensor module directly to the support pole.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a conveyor system including a conveyorbelt, conveyor belt cleaners, and sensors associated with the conveyorbelt cleaners configured to transmit signals regarding properties of thebelt cleaners over a wireless network;

FIG. 1B is a perspective view of the conveyor belt and one of theconveyor belt cleaners of the conveyor system of FIG. 1A;

FIG. 1C is a perspective view of another conveyor system including anupper conveyor system having conveyor belt cleaners, a lower conveyorsystem having an impact bed, and a transfer chute system for guidingdischarged material from the upper conveyor system onto a loading zoneof the lower conveyor system at the impact bed;

FIG. 2A is a perspective view of a sensor module for being mounted on asupport pole of one of the conveyor belt cleaners of FIG. 1A to monitorone or more properties of the belt cleaner;

FIG. 2B is a cross-sectional view of the sensor of FIG. 2A;

FIG. 3 is a network diagram illustrating the wireless communication ofsensors of the conveyor system of FIG. 1A with a control system by wayof a wireless gateway and a cloud computing system;

FIG. 4 is a network diagram illustrating the wireless communication ofsensors of the conveyor system of FIG. 1A with a control system by wayof a wireless gateway and cloud storage as well as a second cloudcomputing system for providing additional parameters to the controlsystem;

FIG. 5 is an illustration of a computer monitor displaying anapplication that provides information to a user based on data measuredby the sensors in the conveyor system of FIG. 1A;

FIG. 6 is an illustration of a computer monitor displaying anapplication that provides information to a user based on data measuredby the sensors in the conveyor system of FIG. 1A;

FIG. 7 is an illustration of a computer monitor displaying anapplication that provides information to a user based on data measuredby the sensors in the conveyor system of FIG. 1A;

FIG. 8 is an illustration of a computer monitor displaying an email thatprovides information to a user based on data measured by the sensors inthe conveyor system of FIG. 1A;

FIG. 9 is an illustration of a computer monitor displaying an email thatprovides information to a user based on data measured by the sensors inthe conveyor system of FIG. 1A;

FIG. 10 is a perspective view of a smartphone displaying an applicationthat provides information to a user based on data measured by thesensors in the conveyor system of FIG. 1A;

FIG. 11 is a perspective view of a tracking device having a sensor, thetracking device being suitable for use in the conveyor system of FIG. 1Aor FIG. 1C;

FIG. 12 is a perspective view of another tracking device having asensor, the tracking device being suitable for use in the conveyorsystem of FIG. 1A or FIG. 1C;

FIGS. 13A, 13B, and 13C are, respectively, a perspective view, across-sectional view, and an exploded view of a self-contained sensormodule for use in the conveyor system of FIG. 1A or FIG. 1C;

FIG. 14 is a perspective view of the sensor module of FIG. 13 having apower cord;

FIG. 15 is a perspective view of a sensor module for use in the conveyorsystem of FIG. 1A or FIG. 1C, the sensor module having a body membersized to fit within a support pole of one of the conveyor belt cleanersof the conveyor belt system;

FIG. 16A is a perspective view of a primary belt cleaner of the conveyorsystem of FIG. 1A;

FIG. 16B is a perspective view of a secondary belt cleaner of theconveyor system of FIG. 1A;

FIGS. 17A, 17B, and 17C illustrate a method for monitoring the conditionof a conveyor belt of the conveyor system of FIG. 1A or FIG. 1C;

FIG. 18 is a block diagram of a sensor circuit of a sensor module thatincludes sensors for detecting movement;

FIG. 19 is a block diagram of a communication hub for communicating withthe sensor circuit of FIG. 18;

FIG. 20A is a perspective view of a sensor module mounted on a tensionbracket of a conveyor belt cleaner for use in the conveyor system ofFIG. 1A or FIG. 1C;

FIG. 20B is an exploded view of the tension bracket and sensor moduleassembly of FIG. 20A;

FIG. 21 is a collection of graphs showing acceleration amplitude versustime as measured by the sensor module of FIGS. 2A-2B at different beltcleaner tensions;

FIG. 22 is a perspective view of the conveyor system of FIG. 1A whereinthe sensor modules communicate over a cellular communication network;

FIG. 23 is a block diagram of a system for monitoring an ancillarydevice of a conveyor system;

FIG. 24A is a front elevational view of a sensor module for beingmounted to a support pole of a conveyor belt cleaner to monitor one ormore characteristics of the conveyor belt cleaner;

FIG. 24B is a rear elevational view of the sensor module of FIG. 24A;and

FIG. 25 is a flow diagram illustrating a setup method for the sensor ofFIGS. 24A and 24B.

FIG. 26 is a perspective view of a sensor module connected to a conveyorbelt cleaner showing a support pole of the conveyor belt cleaner clampedbetween a housing upper portion and a housing lower portion of thesensor module;

FIG. 27 is an exploded, perspective view of the sensor module of FIG. 26showing a circuit board, a circuit board support, and a battery that arereceived within a compartment of the housing lower portion;

FIG. 28 is a schematic representation of a smartphone being used tosetup the sensor module of FIG. 26 and the sensor module communicatinginformation to a remote server;

FIG. 29 is a perspective view of a pole extender including a body havingspaced, arcuate walls sized to fit within an opening of a support poleof a conveyor belt cleaner and a cylindrical outer surface to which thesensor module of FIG. 26 may be attached;

FIG. 30 is a cross-sectional view taken across line 30-30 in FIG. 29showing an actuator bolt of the pole extender in threaded engagementwith a spreader of the pole extender;

FIG. 31 is a cross-sectional view of the spreader taken across line31-31 in FIG. 29 showing cam walls of the spreader having inclinedsurfaces for spreading apart the arcuate walls of the body and securingthe pole extender to the support pole;

FIG. 32 is a cross-sectional view of the pole extender taken across line31-31 in FIG. 29 showing the pole extender connected to a support poleof a conveyor belt cleaner, the conveyor belt cleaner having a mount atan end of the support pole that limits placement of a sensor module onthe support pole;

FIG. 33 is a view similar to FIG. 32 showing the actuator bolt havingbeen tightened to draw the wedge toward the body and urge the arcuatewalls of the body against an inner surface of the support pole; and

FIG. 34 is a graph showing data from an accelerometer mounted to asupport pole of a conveyor belt cleaner showing changes in the frequencydomain response of signals from the accelerometer with changes in theoperating conditions of the associated conveyor belt system.

DETAILED DESCRIPTION

In accordance with one aspect of the present disclosure, an apparatus isprovided for monitoring a conveyor system. The apparatus may include oneor more sensors associated with conveyor belts as well as ancillarydevices of the conveyor system, such as idler rollers, cleaners,trackers, and/or impact beds. The one or more sensors may be associatedwith the ancillary devices in a number of approaches, such as beingintegrated with the ancillary devices, mounted to the ancillary devices,and/or mounted to frame members of the structure supporting the conveyorbelt proximate the ancillary devices.

The ancillary devices may include portions with relatively shortexpected lifespans, or replaceable portions, and portions withrelatively long expected lifespans, or permanent portions. Althoughreferred to herein as being “permanent,” the permanent portions maydeteriorate over time and are capable of being replaced. The permanentportions have a longer predicted lifespan and are designed to outlastthe “replaceable portions.” For example, the replaceable portion of abelt cleaner may be the scraping blade of the belt cleaner and thepermanent portion of the belt cleaner may be the housing or anelongated, rigid mounting structure, such as a base member or supportpole, of the belt cleaner. As another example, the permanent portion isa portion of a frame of the conveyor system to which the ancillarydevices are mounted.

The one or more sensors of the apparatus may be mounted to, integratedwith, and/or proximate the permanent portion(s) of one or more ancillarydevices. The sensors detect one or more characteristics of the ancillarydevice, such as acceleration. The acceleration may be due to, forexample, jarring impacts against a portion of the ancillary device suchas a splice impacting a scraper blade of a conveyor belt cleaner. Thesensors may also detect one or more characteristics of a conveyor belt,such as by using an optical sensor to detect carry-back on a return runof the conveyor belt. The sensors may also detect sound. Sound can beused to detect if the belt is running, and specific sounds can bemonitored for which may indicate debris on the belt, an impact with acleaner, or a failed bearing in one of the rollers. The sensors may alsodetect one or more ambient conditions, such as temperature and humidity.The sensors may also detect the temperature of one or more components ofthe ancillary device.

The apparatus may include a processor and the measured datacorresponding to the detected one or more characteristics is transmittedto the processor. The processor identifies fault conditions, such as aworn out or broken ancillary device, in the conveyor system based on themeasured data. In one form, the processor is a local processor directlyconnected to the sensor. In another form, the processor is a remotecomputing device that receives the data from one or more sensor moduleover a wired and/or wireless communication network. In some forms, eachsensor module communicates directly with a communication hub, such as arouter. In another form, the sensor modules form a mesh network, inwhich a first sensor module acts as a communication relay for a secondsensor module, the second sensor module acts as a communication relayfor a third sensor module, and so on. The ability of the sensor modulesto operate as communication relays allows sensor modules that would havedifficulty directly communicating with a communication hub of the systemto still provide data to the processor. For example, the communicationhub may be positioned at the beginning of an underground mine. The firstsensor module is closest to the communication hub while the second andthird sensor modules are progressively farther into the mine. Althoughthe second and third sensor modules may be unable to communicatedirectly with the communication hub due to interference from the rock ofthe mine, data from the third sensor module may be relayed by the secondsensor module to the first sensor module which in turn relays theinformation to the communication hub. Likewise, the data from the secondsensor module may be relayed by the first sensor module to thecommunication hub. In other forms, one or more of the sensor modulesinclude a cellular communication card, such as a Global System forMobile Communications (“GSM”) card and communicate via a cellularnetwork.

In one approach, the processor identifies a fault condition by comparingthe measured data to a minimum threshold value, a maximum thresholdvalue, or to an acceptable range of values. For example, data from anaccelerometer detecting acceleration of an idler roller is compared to amaximum threshold value. If the acceleration exceeds the maximumthreshold value, the processor identifies a fault because the highacceleration may indicate that the idler is not rotating or somecondition or set of conditions is causing the conveyor belt to vibrateproximate the idler roller. In another example, the processor receivesdata from an accelerometer configured to measure acceleration of aconveyor belt cleaner and compares the acceleration values to anacceptable range of acceleration values. If the measured accelerationvalues are too low, the processor may identify a fault condition becausethe low acceleration values may be the result of the scraper blade ofthe conveyor belt cleaner not engaging the conveyor belt. If themeasured acceleration values are too high, the processor may identify afault condition because the high acceleration values may be the resultof the scraper blade riding along the residue on the conveyor beltinstead of scraping the residue off, for example if the blade has becometoo worn.

In one form, the processor monitors data outputs from the one or moresensors over a period of time to identify trends that may indicate afault in the conveyor system. For example, the processor may use datafrom an accelerometer detecting acceleration of a tracker to identifythe frequency of corrective actions undertaken by the tracker. If theprocessor determines the frequency of corrective actions exceeds athreshold value, the processor identifies a fault condition because thefrequency of corrective actions may indicate that some condition or setof conditions is causing the conveyor belt to continuously drift in onedirection. In one form, the apparatus includes a memory configured tostore data outputs from the one or more sensors. The processor isoperatively coupled to the memory and may retrieve information regardingthe sensor data outputs from the memory such as to determine historicaltrends in the sensor data outputs.

The apparatus may also include a user interface operatively coupled tothe processor and configured for displaying identified fault conditionsto a user. In some forms, the user interface is a remote computingdevice usable remote from the monitored conveyor belt system. Theprocessor may include a local computer in the facility containing themonitored conveyor belt system and the user interface may include aremote computing device operated by a user. For example, the userinterface may include a personal computer, laptop computer, smartphone,or a tablet computer. If the user interface is a portable device such asa smartphone or tablet computer, the local computer may transmit analert such as an email or a notification to the portable device in theevent of a failure condition.

With reference to FIGS. 1A, 1B, and 1C, conveyor systems 100, 100A areprovided that include conveyor belts 102 and a number of ancillarydevices, such as impact beds 110, belt cleaners 120, idler rollers 130,drive rollers 135, and trackers 140. The conveyor systems 100, 100A maybe components of a larger conveyor system, may be separate systems at acommon location, or separate systems at separate locations as someexamples. Regarding FIG. 3, the conveyor systems 100, 100A include amonitoring system 10 for monitoring one or more characteristics of oneor more components of the conveyor systems 100, 100A. The monitoringsystem 10 incudes sensor modules 112, 122, 132, 142 positioned at one ormore components of the conveyor systems 100, 100A. The sensor modules112, 122, 132, 142 each include one or more sensors and a communicationmodule. The sensor modules 112, 122, 132, 142 are configured to detectone or more conditions of the one or more components based on, forexample, movements of components or portions thereof. The monitoringsystem 10 includes a remote resource, such as cloud computing system105, that processes data from the sensor modules 112, 122, 132, 142 todetermine one or more characteristics of the corresponding ancillarydevices and conveyor belt 102 and/or to predict properties of theancillary devices and conveyor belt 102 such as the remaining lifespanthereof. The cloud computing system 105 is operable to predict otherproperties of the conveyor system 100, such as whether the belt isrunning, how long the belt has been running, whether the ancillarydevice is properly engaged with the belt 102, the amount of carryback,and the presence or absence of material on the belt 102. The cloudcomputing system 105 may include one or more remote servers providingcloud computing functionality.

The sensor modules 112, 122, 132, 142 communicate with the cloudcomputing system 105 by way of a gateway 104. The gateway 104 is aninternet router or cellular tower which connects the sensor modules 112,122, 132, 142 to the internet. Information from the cloud is viewed by auser through a computer 107 (see FIG. 3) or smartphone 106. The computer107 is part of a control system 101, such as a computer configured tocontrol the conveyor system 100. Although a desktop computer 107 and asmartphone 106 are shown in FIG. 3, other computing devices may beutilized such as a laptop computer, a tablet computer, a smartwatch, andaugmented reality glasses.

With reference to FIGS. 1A and 1B, the idler rollers 130 and driverollers 135 of the system 100 are rotatably coupled to a frame 103. Theconveyor belt 102 is a continuous belt extending around the plurality ofidler rollers 120 and drive rollers 135 such that the conveyor belt 102travels relative to the frame 103 along a path. The belt cleaners 120each include a cleaner blade such as a plurality of scraper blades 124that are biased into engagement with the outer surface 1020 of the belt102. The belt cleaners 120 include a pre-cleaner or primary belt cleaner120A and a secondary belt cleaner 120B. The primary belt cleaner 120A ispositioned at the head or drive pulley 135 so as to remove material fromthe belt 102 and assist discharging the material from the conveyor belt102. The secondary belt cleaner 120B is positioned along the return runof the conveyor belt 102 to provide additional cleaning of the conveyorbelt 102 and limit “carry-back” of material. In other words, thesecondary belt cleaner 120B ensures the material is discharged from theconveyor belt 102 rather than traveling back to a tail drive roller 135of the conveyor belt 102.

In some forms, the primary belt cleaner 120A is configured to be rotatedinto engagement with the belt 102. In some forms, the secondary beltcleaner 120B is configured to move vertically, in a linear directionsubstantially normal to the surface of the belt 102, into engagementwith the belt 102.

An example of the primary belt cleaner 120A is provided in FIG. 16A. Thebelt cleaner 120A includes one or more scraper blades 124 mounted to anelongate support such as a support pole 126. The scraper blade 124 canbe made of a variety of materials, such as steel, carbide, or urethane.The scraper blade 124 may be a scraper blade assembly having a resilientbody portion, such as an elastomeric or polymeric body portion, and ahard blade tip, such as a carbide tip. Each scraper blade assembly mayalso include a base, such as U-shaped metallic bracket, which is boltedto the support pole 126. The body portion resiliently biases the scraperblade against the conveyor belt and resiliently deforms to permit thescraper blade to deflect out of the way of an imperfection of theconveyor belt 102 such as fastener on the belt. The support pole 126includes end portions 1626, 1627 that are connected to mounts 1603, 1604and an intermediate portion 1625 that is releasably connected to the endportions 1626, 1627. The releasable connection permits the intermediateportion 1625 and the scraper blades 124 connected thereto to be easilyremoved for maintenance. The mounts 1603, 1604 are configured to besecured to the frame 103 of the conveyor belt 102, such as by welding orfasteners.

The mounts 1626, 1627 permit controlled turning of the support pole 126in directions 126A, 126B. The mounts 1603, 1604 each include a tensionbracket 1670 having a collar 1671 secured to the support pole 126 and aspring 1601. The spring 1601 resiliently biases the scraper blades 124against the conveyer belt 120. The mounts 1603, 1604 permit the supportpole 126 to turn in direction 126A in response to an impact against thescraper blades 124, such as a fastener of the conveyor belt 102 strikingthe scraper blades 124. Turning of the support pole 126 in direction126A causes the tension bracket 1670 to compress the spring 1601. Thecompressed spring 1601 then urges the tension bracket 1670 back towardits initial position which moves the scraper blades 124 back intoengagement with the conveyor belt 102.

In some forms, the scraper blades 1624 include a communication circuitfor communicating with the sensor module 122, such as an RFID chip 1629.Regarding FIG. 2B, the sensor module 122 includes a sensor circuit 123having an RFID reader such as RFID sensor 1803 (see FIG. 18) thatidentifies the one or more scraper blades 124 by reading the RFID chip1629 of the one or more scraper blades 124. In one form, the RFID chip1629 (see FIG. 16A) is a near field chip or non-powered chip. The RFIDreader 127 creates a magnetic field which induces a current in the RFIDchip 1629. The induced current is used to transmit a code. In someforms, the control system 101 uses identifying information about thescraper blades 124, such as the model of the scraper blades 124 and/ormaterial the scraper blades 124 are formed of, in the analysis of thedata from the sensor module 122. For example, a carbide scraper blademay be expected to vibrate more in standard use than a urethane scraperblade. Alternatively or additionally, the sensing of the RFID chip 1629is used to detect the presence of a scraper blade 1624. If no RFID chip1629 is detected, the sensor module 122 transmits a signal to thecontrol system 101 indicating that no scraper blade 124 is present.Still further, the control system 101 may be configured to determinewhether the incorrect scraper blade 1624 is installed based on thereading of the RFID chip 1629.

An example of the secondary belt cleaner 120B is shown in FIG. 16B. Thebelt cleaner 120B includes one or more scraper blades 1684 mounted to anelongate support, such as the support pole 1688. The scraper blades 1684can be made of a variety of materials, such as steel, carbide, orurethane. The support pole 1688 includes end portions 1686, 1687 thatare connected to mounts 1663, 1664 and an intermediate portion 1685 thatis connected to the end portions 1686, 1687. The scraper blades 1684 arereleasably connected to the intermediate portion 1685, allowing thescraper blades 1684 to be easily removed for maintenance. The mounts1663, 1664 are configured to be secured to the frame 103 of the conveyorbelt 102, such as by welding or fasteners.

The mounts 1663, 1664 permit controlled linear movement of the supportpole 1688 in directions 1661A and 1661B. A pair of springs 1661 urge thesupport pole 1688 and thus the scraper blades 1684 toward the belt 102in direction 1661B. The mounts 1663, 1664 permit the support pole 1688to move in direction 1661A in response to an impact against the scraperblades 1684, such as a damaged fastener of the conveyor belt 102striking the scraper blades 1684. Movement of the support pole 1688 indirection 1661A causes compression of the springs 1661. The compressedsprings 1661 then urge the support pole 1688 in the direction 1661B backinto engagement with the belt 102. As described below, one or moresensor modules 122 can be coupled to the support pole 1688 to detectmovement of the scraper blades 124. Other belt cleaners are described inU.S. Pat. Nos. 7,093,706; 7,347,315; 8,757,360; and 9,586,765 which allare hereby incorporated by reference in their entireties.

The mounts 1663, 1664 include square-shaped housings 1636 and sleevemembers 1638 which permit controlled turning of the support pole 1688about a longitudinal axis 1688A of the support pole 1688. The endportions 1686, 1687 extend through the square-shaped housings 1636 andare secured to the sleeve members 1638. A resilient material 1640 ispositioned between the inner walls of the rectangular housing 1636 andthe outer walls of the sleeve members 1638. In operation, frictionbetween the scraper blades 124 and the belt 102 turns the support pole1688. The resilient material 1640 resists the turning and biases thesleeve members 1638 back toward the illustrated position so as tomaintain engagement between the scraper blades 1684 and belt 102.

Returning to FIG. 1C, the conveyor system 100A has two belts 102including an upper belt 102U and a lower belt 102L. The upper belt 102Uis cleaned by belt cleaners 120 having sensor modules 122. Materialconveyed by the upper belt 102U is discharged into a chute 108. Thechute 108 guides the discharged material onto a loading zone of thelower belt 102L. The lower belt 102L is supported at the loading zone byan impact bed 110.

The scrapers 120, impact bed 110, and other ancillary devices aresupported by a frame 203 of the conveyor system 100A and engage the belt102. In one form, the sensor modules 112, 122, 132, and/or 142 arecoupled to the frame 103 proximate to the coupling of the frame 103 andthe corresponding ancillary device. Movement of portions of theancillary devices causes the frame 103 to vibrate, and the sensormodules 112, 122, 132, and/or 142 measure this vibration.

Regarding FIG. 1A, the conveyor system 100 further includes acommunication hub 104, such as a wireless router, which wirelesslycommunicates with a plurality of sensor modules 112, 122, 132, and 142.The wireless communication between the sensor modules 112, 122, 132, and142 and communication hub 104 may utilize any of a variety ofcommunication protocols. For example, the sensor modules 112, 122, 132,142 may use infrastructure protocols such as 6LowPAN, IPv4/Ipv6, RPL,QUIC, Aeron, uIP, DTLS, ROLL/RPL, NanoIP, CNN, and TSMP; identificationprotocols such as EPC, uCode, Ipv6, and URIs; communication/transportprotocols such as Wifi, Bluetooth®, DigiMesh, ANT, NFC, WirelessHart,IEEE 802.15.4, Zigbee, EnOcean, WiMax, and LPWAN; discovery protocolssuch as Physical Web, mDNS, HyperCat, UpnP, and DNS-SD; Data protocolssuch as MQTT, MQTT-SN, Mosquitto, IMB MessageSight, STOMP, XMPP,XMPP-IoT, CoAP, AMQP, Websocket and Node; device management protocolssuch as TR-069 and OMA-DM; semantic JSON-LD and Web Thing Model; and/ormulti-layer frame work protocols such as Alljoyn, IoTivity, Weave, andHomekit.

In some forms, the communication hub 104 communicates with an externaldata processing system, such as a cloud-based computing system 105 asshown in FIG. 1A. The cloud-based computing system 105 may storecommunicated data and/or process the communicated data and relay databack to the communication hub 104 or another computer system for furtherprocessing or storage. For example, the cloud-based computing system 105may include one or more data processing applications configured to runon a virtual machine in the cloud-based computing system 105 and processthe data communicated to the cloud-based computing system 105 by thecommunication hub 104. Alternatively or additionally, the communicationhub 104 transmits data from the sensor modules 112, 122, 132, and 142 toone or more onsite computers such as a control room computer or portablecomputers, e.g., smartphones or tablets, carried by users of theconveyor system 100. The sensor modules 112, 122, 132, and 142 may alsotransmit data directly to the one or more onsite computers using one ormore communication protocols such as those listed above. Furthermore,the sensor modules 112, 122, 132, 142 may transmit data between eachother or other sensors before communicating data to the one or moreon-site computers, the communication hub 104, and/or the cloud-basedcomputing system 105. The communication hub 104 may use the sameprotocols or different protocols when communicating with the cloud-basedcomputing system 105, an on-site computer, or another external device.

FIG. 18 illustrates a sensor circuit 1800 that may be utilized as partof the sensor modules 112, 122, 132, and 142 described above. The sensorcircuit 1800 includes a processor 1802 communicatively coupled to amemory 1804, a communication module 1806, and one or more sensors 1807A.The memory unit 1804 is non-transitory computer readable memory, such asrandom access memory (RAM), solid state memory, or magnetic disc-basedmemory.

A power source 1801, such as a direct electric connection (e.g., a wiredconnection) and/or a battery, powers the processor 1802, memory 1804,communication module 1806 and sensors 1807A. The sensor modules 112,122, 132, and 142 may be configured to run on the battery if the directelectric connection is disconnected and transmit an alert indicatingthat the direct electric connection has been disconnected. In someforms, the power source 1801 includes a charger or generator thatincludes one or more inertial damping mechanisms such as a flywheel,pendulum, shock absorber, or rotary damper capable of converting kineticenergy to electric energy and charging the battery. For example, as thesensor modules 112, 122, 132, and 142 vibrate due to operation of theconveyor system 100, 100A, the batteries of the sensors 1807A arecharged.

In one form, the one or more sensors 1807A include a gyroscope 1807, anaccelerometer 1808, and a magnetometer 1809. The sensors 1807A detectmovement of the corresponding ancillary device. Data representing thedetected movement is transmitted to the processor 1802. The processor1802 writes the received data to the memory 1804. Additionally oralternatively, the processor 1802 operates the communication module 1806to wirelessly transmit the data representative of the detected movementto an external device using one or more of the standards listed above.

The sensor modules 112, 122, 132, and 142 may include, for example,digital or analog accelerometers 1808 having one, two, or three axes;digital or analog gyroscopes 1807 having one, two, or three axes; and/ora magnetometer 1809 such as a MEMS magnetic field sensor. As such thesensor modules 112, 122, 132, and 142 may have three, six, or nine axesof sensing. The accelerometers may be configured to measure one or morestatic or dynamic forces being applied to ancillary devices 110, 120,and 130 of a conveyor belt system. The gyroscopes may be used todetermine the number and rate of rotation of portions of the ancillarydevices 110, 120, and 130, such as turning of the support pole 126 (seeFIG. 16A) in directions 126A, 126B in space. The magnetometer mayprovide absolute angular measurements of portions of the ancillarydevices 110, 120, and 130, such as turning of the support pole 126 indirection 126A, 126B relative to the earth's magnetic field. The sensormodules 112, 122, 132, and 142 may further include a processor forprocessing sensed data, one or more memories for storing and processingsensed data, and one or more communication modules for communicatingwith various external devices. The one or more communications modulesmay communicate with the external devices using one or more of theprotocols listed above.

In one form, the memory unit 1804 stores routines for processing thedata output by the sensors 1807, 1808, and 1809. The processor 1802 runsthe stored routines to process the data. The results of the routines aretransmitted by the communication module 1806.

In one form, the communication module 1806 transmits the data to thecommunication hub 104 (see FIG. 1A) via a wired or wireless connection.Turning to FIG. 19, the communication hub 104 includes a processor 1902,a memory 1904, a first communication module 1906 and a secondcommunication module 1908. The first communication module 1906communicates using the same communication protocol as the communicationmodule 1806. The first communication module 1906 receives the data fromthe communication modules 1806 of multiple local sensor circuits 1800.The received data is transmitted from the first communication module1906 to the processor 1902.

The processor 1902 operates the second communication module 1908 totransmit the received data to a remote resource. In one form, the remoteresource is a remote onsite computer. In another form, the remoteresource is offsite, for example a cloud-based server system. The datais then processed and/or displayed as described below.

In one form, the communication module 1806 is a cellular communicationmodule. The communication module 1806 is configured to communicate overa standard cellular communication protocol, such as GSM. FIG. 22illustrates the conveyor system 100 in which the sensor modules 122include cellular communication modules 1806. The sensor modules 122communicate with the central control system 101 over the internet 105 byway of a cellular phone tower 2201. In some forms, the communicationmodule 1806 is configured to communicate over a low-power wide-areanetwork, such as LTE CAT-M1 or NB-IoT. The communication module 1806includes a fallback communication protocol, such as 2G cellularcommunications.

In one form, the communication module 1806 of the sensor circuit 1800includes the RFID sensor 1803. The RFID sensor 1803 is configured todetect nearby RFID chips. RFID chips can be coupled to the replaceableportions of the ancillary devices 110, 120, 130, and 140. The RFIDsensor 1803 detects the presence of the replaceable portion by detectingthe RFID chip. Alternatively or additionally, the RFID sensor 1803receives identifying information from the RFID chip. For example, theRFID sensor 1803 may detect the RFID chip 1629 described above toidentify the model number of the scraper blade 1624. The processor 1802or the central control system 101 uses the identifying information toselect the stored values to which the data from the sensors 1807A arecompared.

In some forms, the RFID sensor 1803 only detects for RFID chips atspecific times, such as when a button on the sensor module 122 ispressed. This reduces the amount of power used by the RFID sensor 1803in comparison to if the RFID sensor 1803 were constantly scanning. Inoperation, a user presses the button when the new wear component orreplaceable component is installed so that the RFID sensor 1803 ispowered and detects the RFID chip. The RFID sensor 1803 may alsoperiodically operate to detect the RFID chip so that the control system101 can determine whether the replaceable component is still present inthe ancillary device.

The sensor modules 112, 122, 132, and 142 may be configured to sensedata continuously but only transmit a portion of the data in order toreduce the amount of data that needs to be processed. For example, thesensor module 122 includes the accelerometer 1808 and may sample thesensed data every second and transmit the sampled data to thecloud-based computing system 105 for processing. Sampling data at afixed interval allows system users to control their data costs. However,at times, additional samples may be utilized to confirm one of more ofthe various fault conditions discussed in detail below. In this case,the cloud based computing system 105, or another external device such asa computer, may temporarily increase the sampling rate of a particularsensor module 112, 122, 132, 142 in order to confirm a fault conditionexists. Generally, the sampling rate of the sensor modules 112, 122,132, and 142 may be increased or decreased as desired for particularsituations. In some forms, the sensor modules 112, 122, 132, and 142maintain a consistent sampling rate for sensors 1807A contained therein,such as thirty samples per second, but internally process the data toreduce the amount of data being transmitted by the sensor modules 112,122, 132, and 142. For example, the detected values may be averagedtogether over a period of time to obtain a single value for that periodof time. Another approach is to utilize a fast Fourier transform toreduce the number and/or complexity of the detected values.

Each of the ancillary devices 110, 120, 130, 140 include a morepermanent portion, such as a frame or body, and a replaceable portionusually configured to engage the conveyor belt 102. In some forms, thepermanent portion is a portion of the frame 103 to which the ancillarydevices 110, 120, 130, 140 are mounted. The sensor modules 112, 122,132, and 142 may be coupled to the more permanent portions of theancillary devices 110, 120, 130, 140 such that they do not need to bereplaced when the replaceable portions are replaced.

Returning to FIG. 1B, the belt cleaner 120 has a support pole 126 andone or more replaceable scraper blades 124. The scraper blades 124 areurged against the outer conveying surface 1020 of the belt 102 to removeany debris or residue that remains stuck to the belt 102 after theconveyed material is discharged therefrom. The friction between thescraper blades 124 and the belt 102 and/or debris from material carriedby the belt 102 wear down the scraper blades 124 over time. The belt 102also includes one or more splices. The splices are typically raisedrelative to the outer surface 1020 of the belt 102. The splices oftencomprise fasteners that are coupled to the belt by staples, rivets, orother fastening members. The engagement between the scraper blades 124and the belt 102 causes the scraper blades 124 to impact the splices,which further contributes to the wearing down or damaging of the scraperblades 124. When the scraper blades 124 become too worn or damaged, theyno longer effectively clean the belt 102 and need to be replaced.

With reference to FIGS. 1B and 16A, the support pole 126 of the primarycleaner 120A is connected to the frame 103 at mounts 1603, 1604. Thesupport pole 126 is not a wear component and has an expected life timeseveral times that of the scraper blades 124. As shown in FIG. 2B, thesensor module 122 includes a housing 125 adapted to be connected to thesupport pole 126 and a sensor circuit 123 within the housing 125. Thesensor circuit 123 is substantially similar to the circuit 1800described above.

With reference to FIGS. 2A, 2B, the housing 125 includes a mountingportion or plug portion 157 sized and shaped to extend at leastpartially into an opening 156 of the support pole 126 and form a plugfit therewith. The plug portion 157 shown has a substantially circularcross-section to fit securely into the substantially circular opening156. In forms in which the support pole 126 has a different shapedopening 156, the plug portion 157 similarly has a differently shapedcross-section to couple thereto. The housing 125 further includes anouter portion 158 configured to remain outside of the support pole 126.The outer portion 158 and plug portion 157 define an annular recess 159therebetween into which a portion of the support pole 126 is received.The outer portion 158 includes a sleeve 158A that surrounds an endportion 126E of the support pole 126 and firmly retains the sensormodule 122 on the support pole 126. Further, fasteners, bands, and/orlocking members may be used to secure the sensor module 122 to thesupport pole 126.

The housing 124 is configured to withstand harsh and/or outdoorenvironments. The housing may have a bright color, such as white, toreduce heating of the sensor module 122 by sunlight. The housing 124 maybe formed of a rigid material to reduce the risk of breaking in theharsh environments of the conveyor systems 100, 100A. Exemplarymaterials include rigid composites, metal alloys, metals, or plastics.Additionally, the sensor circuit 123 may be embedded in a pottingmaterial to reduce the likelihood of being damaged by the vibrationand/or impacts experience by the sensor module 122.

With reference to FIG. 2B, the housing 125 includes a cavity 121positioned at least partially in the plug portion 157. The cavity 121 issized to receive the sensor circuit 123. In one form, a power source,such as batteries 129, are also positioned in the cavity 121.Alternatively, the housing 125 includes separate internal cavities 121for the sensor circuit 123 and batteries 129. In one form, the cavity121 extends at least partially into the outer portion 158 beyond the endof the recess 159 such that an antenna 128 of the sensor circuit 123 ispositioned beyond the end portion 126E. In this manner, wireless signalstransmitted and/or received via the antenna 128 are not blocked by thesupport pole 126.

In operation, the scraper blades 124 vibrate as they scrape against therunning belt 102. The vibration of the scraper blades 124 in turnvibrates the support pole 126 and the sensor module 122 fitted andsecured to the end portion 126E of the support pole 126. If the scraperblades 124 become too dull, they will slide along debris on the belt 102instead of scraping the debris off. This causes the scraper 120 to movedifferently, such as by the support pole 126 rotating a differentangular amount, and/or vibrate differently, such as at greater frequencyand/or amplitude, than when the scraper 120 is working correctly.Alternatively, the scraper blades 124 may be worn down, broken, orpushed back to the point that the scraper blades 124 no longer engagethe belt 102. This causes the scraper 120 to vibrate less than or not atall it would if the scraper 120 were in proper working condition.

In one form, the sensor circuit 123 includes a processor 171 configuredto compare the vibration of the scraper 120 to an acceptable rangestored in the sensor circuit 123. If the vibration falls outside of theacceptable range, one or more faults are detected and the processor 171sends a signal indicating the fault via the transmitter 172 utilizingthe antenna 128. The acceptable ranges stored on the sensor circuit 123may be updated by communication with an external device. In anotherform, the sensor circuit 123 transmits the raw data from the sensor 173,such as an accelerometer, and a processor at a different location suchas the in the cloud-based computing system 105 or at a central controlcomputer performs the processing.

The sensor circuit 123 can be used to predict one or more properties ofone or more components of the conveyor system 100. For example, the oneor more properties may include whether or not the conveyor belt 102 ismoving. When the conveyor belt 102 is moving, the sensor module 122 isvibrated and the at least one characteristic of the support pole 126,such as acceleration, can be detected by an accelerometer in the sensorcircuit 123. When the sensor 123 detects vibration with low frequency orlow magnitude, it can indicate that the belt 102 is running whileloaded.

The sensor circuit 123 may be used to predict other properties of thecomponents of the conveyor belt system 100. For example, the sensorcircuit 123 may be used to detect whether the cleaner 120 is engagingthe belt 102 or is backed off. In one form, engagement is detected basedon vibration which is detected by an accelerometer 173 of the sensorcircuit 123. In forms in which the belt cleaner 120 rotates intoengagement with the belt 102, such as the belt cleaner 120A of FIG. 16A,engagement can be detected based on the rotation of the support pole126. The sensor circuit 123 can detect a characteristic of the supportpole 126, such as rate of rotation or position, with a gyroscopic sensoror a level sensor, such as a mercury switch. In some forms, the sensorcircuit 123 detects rotation or orientation using an accelerometer bytracking the history of movement. If an accelerometer is used to trackorientation, the sensor circuit 123 may be calibrated periodically toreduce compounding error. In another example, the sensor circuit 123predicts when the scraper blades 124 are backed off of the belt 102 byway of a limit switch configured to detect when the support pole 126 isfully rotated by the spring 1601.

The sensor circuit 123 may also use the characteristic of orientation ofthe support pole 126 to predict a property of the scraper blades 124,such as wear level of the scraper blades 124. As the scraper blades 124wear down, the base member 126 is rotated farther to keep the scraperblades 124 engaged with the belt 102.

The sensor circuit 123 may also use the linear position of alinear-biased conveyor belt cleaner 120B (see FIG. 16B) to predict theproperties of engagement and wear of the scraper blades 124 of theconveyor cleaner 120. The position of the support pole 126 relative tothe frame 103 indicates how far the support pole 126 is being urgedtowards the belt 102. This distance changes as the scraper blades 124wear down. When the support pole 126 reaches the end of its travelabledistance, the scraper blades 124 are worn to the point that they are nolonger properly engaging the belt 102.

The sensor 173 of the sensor circuit 123 may include an accelerometer.The sensor circuit 123 may utilize the accelerometer to predict chatterin the conveyor system 100. Chatter, which is movement within the systemcaused by irregularities of one or more parts (such as idler rollers ordrive rollers), may be predicted using vibrations detected by theaccelerometer. The irregularity causes the part to move irregularly,which moves the belt 102. The belt 102 in turn moves the scraper blades124 which move the support pole 126. The accelerometer can detect boththe magnitude and frequency of the chatter.

The effectiveness of one of the belt cleaners 120 can depend on thetension with which it is urged into engagement with the belt 102. In oneform, the sensor circuit 123 may predict the tension of the belt cleaner120 based on the frequency response of the support pole 126. Forexample, if the belt cleaner 120 is under high tension and the scraperblades 124 are pushed away from the conveyor belt 102 by an impact, thebelt cleaner 120 will quickly return the support pole 126 to theoriginal position of the support pole 126 and re-engage the scraperblades 124 with the conveyor belt 102. Conversely, if the belt cleaner120 is under low tension, the belt cleaner 120 will return the supportpole 126 to the original position thereof and re-engage the scraperblades 124 with the conveyor belt 102 more slowly.

In some forms, the sensor 173 of the sensor circuit 123 may include agyroscope and an accelerometer which are used to predict mistracking ofthe belt 102. Mistracking of the belt 102 can cause twisting of thescraper blades 124 as a result of asymmetrical forces impartedthereupon. The gyroscope and/or accelerometer can detect characteristicsof the support pole 126 as the support pole 126 vibrates that indicatetwisting of the scraper blades 124. Similarly, unevenly worn scraperblades 124 can cause twisting or other movement of the belt cleaner 120that can be detected by the gyroscope and accelerometer of the sensorcircuit 123.

The sensor circuit 123 may also be used to predict other properties ofthe conveyor system 100, such as whether the scraper blade 124 ismissing (even if another portion of the belt cleaner 120 is stillcontacting the belt 102), whether one of the belt cleaners 120 ismissing, whether the scraper blade 124 is chipped (and/or impact eventslikely to cause chipped scraper blades), whether the conveyor belt 102is flapping, and the projected remaining life of the conveyor belt 102.

The sensor circuit 123 may also detect movement of the support pole 126when the scraper blades 124 contact a splice of the conveyor belt 102.In one form, the central control system 101 identifies splices based onthe pattern of movement of the support pole 126 because the splice willbe at the same point of the belt 102 during every complete cycle.Identifying the movements of the scraper blades 124 caused by beltsplices allows the central control system 101 to avoid attributing saidmovement to one of the other characteristics described above, such as adull or damaged scraper blade 124.

FIG. 21 displays example data from an accelerometer of the sensor 173 ofthe sensor circuit 123 wherein the belt 102 of the conveyor system 100has a belt splice. The four graphs 2101, 2102, 2103, and 2104 display,respectively, acceleration amplitude vs. time for tensions of a beltcleaner at 0%, 50%, 100%, and 150% tensions. The tension of a beltcleaner is the amount of force by which the scraper blades 124 are urgedagainst the belt 102 as a percentage of the target tension. The targettension varies based on the material of the scraper blades 124, thematerial of the belt 102, and the material being conveyed. As shown ingraph 2101, when the scraper blades 124 are under no tension, theimpacts 2110 with the splice do not occur at consistent intervals oramplitudes. However, as shown in graphs 2102, 2103, and 2104, when thescraper blades 124 are under tension, the splice impacts the scraperblades on substantially every rotation of the conveyor belt, and thusthe impacts occur at consistent intervals. The central control system101 processes the acceleration amplitude versus time data to identifyaccelerations that take place at consistent intervals. In some forms,the central control system 101 utilizes values representing the speedand length of the conveyor belt 102 to identify acceleration events thatoccur once every rotation. These events are identified as being causedby an imperfection in the belt 102, such as a splice. In some forms,stored values represent the predicted amplitude of acceleration of abelt cleaner 120 from an impact with a splice. The central controlsystem 101 utilizes these stored values to identify acceleration events2110 as impacts with a splice.

FIG. 21 illustrates the change in amplitude of acceleration from impactsas tension changes. In some forms, the central control system 101processes accelerometer data to predict the tension of the belt cleaner120 by comparing recorded data to stored values. In graph 2101, impacts2110 at 0% tension had a mean amplitude of 0.55 m/s². Impacts 2110 at50% tension, see graph 2102, had a mean amplitude of 0.71 m/s². In graph2103, impacts 2110 at 100% tension had a mean amplitude of 0.94 m/s².Lastly, in graph 2104, impacts 2110 at 150% tension had a mean amplitudeof 1.4 m/s². The exact amplitudes will change based on a number of otherfactors, such as splice material, blade material, conveyor speed,environmental factors, etc. However, the trend of higher magnitudes ofacceleration as a result of impact at higher tensions enable the centralcontrol system 101 to estimate the tension when factoring in these othervariables. As seen in graph 2104, the first five impacts 2110 had a meanamplitude of approximately 3 m/s². After the fifth impact, the meanamplitude dropped off to approximately 1 m/s². This sudden drop inmagnitude can indicate damage to the blade 124 or the splice. In someforms, the central control system 101 will flag a sudden change inamplitude, such as that shown in the graph 2104, and transmit an alertto a user.

Returning to FIGS. 1A and 1B, the idler rollers 130 and drive rollers135 are removably and rotatably mounted to the frame 103. The rollers130, 135 may have a relatively short expected lifespan as a result offriction between the outer surface of the rollers 130, 135 and the belt102 and/or the wear on roller bearings of the rollers 130, 135. As suchthe rollers 130, 135 may be replaced multiple times over the lifetime ofthe conveyor system 100. In one form, sensor modules 132 are mounted tothe frame 103 proximate the idler rollers 130. The movement of the belt102 along the idler rollers 130 cause the rollers 130 and the nearbyportions of the frame 103 to vibrate. The sensor module 132 includes anaccelerometer configured to measure the vibration of one of the idlerrollers 130. If the internal bearings fail, the idler roller 130 maystop rotating or seize. A seized idler roller 130 can be detected bymeasuring a higher than expected amount of vibration. A processor may,either at the sensor module 132 or at a central computer, compare themeasured vibration data to a stored range, and if the vibration measuredis more or less violent than the stored values an alert can betransmitted indicating that the roller 130 is potentially damaged orseized.

The rollers 130 supporting the upper run of the conveyor belt 102 nearthe outer edges thereof are angled such that the outer ends of therollers 130 are higher than the inner ends. This configuration partiallyrolls up the sides of the belt 102, giving the belt 102 a generallyU-shaped or trough-shaped cross-section. The trough-shaped cross-sectionreduces the amount of material that spills off of the belt 102.

Returning to FIG. 1C, the impact bed 110 has one or more resilientsupports or impact bars 114 for supporting an inner surface 1021 of anupper run 201 the conveyor belt 102L where the material falls throughthe chute 108 and onto the conveyor belt 102L. In one form, the impactbars 114 are mounted to a frame 116 which is in turn movably attached tothe frame 203. The frame 116 may attached to the frame 203 via springsthat permit the frame 116 and impact bars 114 to shift downward toabsorb impact and then return to the original positions of the impactbars 114. Additionally, the impact bars 114 may have a laminatedstructure including an upper, belt-contacting layer made of nylon orTeflon and a resilient lower layer that is mounted to the frame 116. Theresilient lower layer may be made of an elastomeric material forexample. The resilient lower layer permits the impact bars 114 tocompress to absorb some of the impact force of the material. Theresilient lower layer of the impact bars 114 impact bars 114 maydecompress when the impact force is removed. The impact bars 114 may bereplaceable members that wear down over time from the impact of theconveyed material as well as friction from the belt 102. The impact bars114 may be detachably coupled to the frame 116 such that they can bereplaced without replacing the frame 116. Impact beds are described inU.S. Pat. No. 7,815,040 which is incorporated by reference herein in itsentirety.

In operation, the material dropped through the chute 108 and onto theouter surface 1020 of the belt 102 causes the belt 102 and impact bars114 and frame 116 of the impact bed 110 to shift downward. The impactbed 110 decelerates the impact bars 114 and frame 116 and then biasesthe impact bars 114 and frame 116 upward back toward the initialposition thereof. The impact bed 110 may include the sensor module 112mounted on the frame 116. The sensor module 112 is substantially similarto the sensor module 122 and includes a sensor circuit similar to thesensor circuits 123, 1800 discussed above. The sensor circuit of thesensor module 112 may include an accelerometer like the accelerometer1808 and a communication module like the communication module 1806. Thesensor module 112 may include a processor like the processor 1802. Theprocessor of the sensor module 112, and/or a processor in a computingdevice external to the sensor module 112, compares data from theaccelerometer to stored baseline values. In some forms, the processor(s)uses additional data representing the timing and weight of payload beingdumped on the conveyor belt 102L to calculate expected movement of theimpact bed 110. If the frame 116 is moving less or more than the rangeof expected values, the processor(s) determine the impact bed 110 is ina fault state and an alert is sent to a user.

With reference to FIG. 11, the conveyor systems 100, 100A may utilizeone or more belt trackers 140 to keep the conveyor belts 102, 102U, 102Ltraveling along predetermined paths. The belt tracker 1140 includes anidler roller 1144 mounted on a pivotal frame 1146 for supporting thebottom surface of the conveyor belt 102, 102U, and 102L and side rollers1145A, 1145B. The pivotal frame 1146 is pivotally connected to a support1147 that extends laterally across the conveyor belt 102, 102U, 102L.The support 1147 is supported by mounts 1103 connected to the frame 103associated with the conveyor belt 102, 102U, 102L. The pivotalconnection between the frame 1146 and the support 1103 permits the frame1146 to pivot about an axis 1146A.

When the belt 102, 102U, 102L creeps in a lateral direction 102B, thebelt 102, 102U, 102L contacts the side roller 1145A causing the frame1146 to pivot relative to the conveyor frame 103. The pivoting of theframe 1146 moves the side roller 1145A upward relative to the conveyorframe 103 and downstream in the direction of travel of the conveyor belt102, 102U, 102L. Because the idler roller 1144 is also mounted to theframe 1146, the end portion 1148 of the idler roller 1146 near the sideroller 1145A also moves upward relative to the conveyor frame 103 anddownstream. Conversely, the pivoting of the frame 1146 due to theconveyor belt 102, 102U, 102L contacting the side roller 1145 moves theside roller 1145B and the end portion 1149 of the idler roller 1144 nearthe side roller 1145 downward relative to the conveyor frame 103 andupstream. This pivoting of the frame 1146 and associated rollers 1144,1145A, 1145B redirects or urges the belt 102, 102U, 102L back toward acentral position.

Over time, the idler roller 1144 and side sensor rollers 1145A, 1145Bmay wear out, with outer surfaces 1143 thereof having relatively shortexpected lifespans. The frame 1146 has a substantially longer expectedlifespan. The belt tracker 1140 may include a sensor module 142 coupledto the pivoting frame 1146. The sensor module 142 may be substantiallysimilar to the sensor module 122 and include a sensor circuit like thesensor circuit 1800. The sensor circuit of the sensor module 142 mayinclude a processor, a wireless transmitter, and a sensor such as anaccelerometer. The sensor of the sensor module 142 detects the directionof pivoting of the frame 1146 as well as the magnitude of pivotingmotion of the frame 1146. The processor of the sensor module 142, and/ora remote processor in an external computing device, analyzes one or morecharacteristics of the pivoting of the frame 1146 over time such asfrequency, direction, and acceleration. A high frequency of pivoting ofthe frame 1146 in one direction can indicate a problem with the conveyorsystem 100, 100A that is causing the belt 102, 102U, 102L tocontinuously creep. Alternatively, very little or no pivoting mayindicate a fault with the tracking device 1140, such as a jam in thepivot connection between the frame 1146 and the support 1147. In someforms, the sensor module 142 senses vibration of the tracking device1140. High vibration may indicate that the roller 1144 is no longerfreely rotating.

FIG. 12 illustrates a belt tracker 1240 usable in place of the belttracker 1140. The belt tracker 1240 is similar in many respects to thebelt tracker 1140. The belt tracker 1240 includes two idler rollers1244A, 1244B detachably coupled to a pivotal frame 1246. The frame 1246is pivotally connected to a support 1247 that is in turn connected tothe conveyor frame 103 via mounts 1203. When the belt 102 creeps in onelateral direction to one of the rollers 1244A, 1244B, the frame 1246pivots about an axis 1246A which moves the one roller 1244A, 1244B inthe downstream, belt travel direction of the conveyor belt 102, 102U,102L. The pivoting of the frame 1246 about axis 1246A may also cause theone roller 1244A, 1244B to tilt so that the one roller 1244A, 1244B israised relative to the other roller 1244A, 1244B. The pivoted rollers1244A, 1244B bias the belt 102, 102U, 102L toward the desired centralposition of the belt 102, 102U, 102L. The belt tracker 1240 may alsoinclude a sensor module 142A mounted to the pivotal frame 1246. Thesensor module 142A is similar to the sensor module 142 of the belttracker 1140.

With reference to FIG. 3, the monitoring apparatus 10 may provide anetwork of interconnected devices for monitoring one or morecharacteristics of one or more components of the conveyor systems 100,100A. For example, the sensor modules 112, 122, 132, 142 associated withthe impact beds 110, belt cleaners 120, idler rollers 130, and belttrackers 140 transmit data to the wireless communication hub 104. Thewireless communication hub 104 in turn transmits the data from thesensor modules 112, 122, 132, and 142 to a remote computer, such as thecloud-based computing system 105. In one form, the wirelesscommunication hub 104 may communicate data from the sensor modules 112,122, 132, and 142 to one or more portable computing devices such assmartphones 106. Further, the wireless communication hub 104 may providedata to sensor modules 112, 122, 132, 142 such as adjusting thresholdvalues for the sensor modules 112, 122, 132, 142 or providing softwareor firmware updates.

The monitoring apparatus 10 includes the central control system 101 thatreceives data from the cloud-based computing system 105 and providescorresponding information to one or more computers 107. The controlsystem 101 includes at least one processor, at least one memory (e.g.,non-transitory computer readable memory, such as RAM, solid state disc,or magnetic disc), and communication circuitry (e.g., WiFi circuitry,Ethernet port, or cellular communication circuitry) configured tocommunicate with the cloud-based computing system 105. The at least onememory of the control system 101 is a non-transitory computer readablemedium such as a magnetic disc. The computer 107 may include a screen, aspeaker, etc. The computer 107 may provide the information to the userusing various approaches, such as using visual, audio, and/or tactileapproaches. In one form, the computer 107 includes one or more computerscreens and the information corresponding to the data from the sensormodules 112, 122, 132, 142 is presented visually on the computer screenssuch as via an internet browser.

The control system 101 processes the data from the sensor modules 112,122, 132, and 142 to determine one or more characteristics of one ormore components of the conveyor system 100, 100A such as the impact bed110, conveyor belt cleaners 120, and idler rollers 130. In one form, thesensor modules 112, 122, and 132 include accelerometers. The controlsystem 101 stores data from the sensors 112, 122, and 132 over time andextrapolates the data to estimate the remaining operational lifetime ofthe impact bed 110, conveyor belt cleaners 120, and idler rollers 130.For example, as the scraper blade 124 of the conveyor belt cleaner 120is dulled, the rotary distance the support pole 126 of the conveyor beltcleaner 120 moves increases. At a certain point, the scraper blade 124will require sharpening or replacement. The control system 101extrapolates the data from the sensor circuit 123 of the sensor module122 to estimate when the scraper blade 124 will require replacement orsharpening. This estimate is used to schedule maintenance so that theconveyor belt cleaner 120 is repaired before breaking, thus reducing therisk of a failing conveyor belt cleaner 120 causing additional damage tothe conveyor system 100, 100A. The control system 101 likewise maydetermine estimates of when maintenance is required for other ancillarydevices such as the impact bed 110, the idler rollers 130, and driveroller 135 based on data from the associated sensor modules 112, 122,132, 142.

In some forms, the control system 101 is provided at a control room atthe same facility as the associated conveyor system 100, 100A.Alternatively, the control system 101 is at a location that isgeographically remote from the facility of the conveyor system 100,100A. By geographically remote, it is intended that the control system101 is separated from the associated conveyor system 100, 100A by one ormiles, two or more miles, three or more miles, hundreds of miles, oreven on different continents. The control system 101 when located remotefrom the facility of the conveyor system 100, 100A may monitor conveyorsystems at geographically dispersed locations.

With reference to FIGS. 5-10, illustrations are provided of an examplecomputer screen of the computer 107 of the control system 101 to showdifferent ways in which the information corresponding to the data formthe sensor modules 112, 122, 132, and 142 may be displayed to a user. Asshown in FIGS. 5-7, the control system 101 may display constant,real-time information about a plurality of ancillary devices. As shownin FIGS. 8-10, the control system 101 provides communicationsperiodically, such as at predetermined times or when a certain conditionis met. These communications may be pushed to a user so that the user isnotified of the condition even if the user is not at his or her desktopcomputer. Alternatively, the user may pull the communications to theuser such as by requesting status information using a smartphone 106(see FIG. 10). In some forms, the control system 101 displays constantreal-time information and provides communications to a user in the eventof a particular condition occurring.

With reference to FIGS. 5-7, the computer 107 is shown displaying theremaining lifetimes of ancillary devices of the conveyor systems 100,100A. In FIG. 5, a table 500 is displayed having information about eachancillary device. The information includes identifying information, suchas the location 552 and an identification number 554, the install date556, and the estimated remaining lifetime 558 in days or weeks. In someforms, the table is color coded to draw attention to devices that are inneed of imminent maintenance. For example, devices that are currently ina failure state are indicated by the color red and devices having ashort remaining life are indicated by the color yellow or orange.

Turning to FIG. 6, the computer 107 displays a bar graph 600 showing thepercentage of remaining life for each ancillary device. Similar to thetable 500, the graph 600 includes the identifying information 652 and654, installation date 656, and bar 658 showing the percentage of liferemaining. In some forms, the bars 658 are color coded as above to drawattention to ancillary devices that are currently in need of maintenanceor will require maintenance shortly.

FIG. 7 illustrates a map 700 or satellite view of the facility orworksite where one or more conveyor systems 100, 100A are positioned.Indicators 750 are positioned on the map 700 at the location ofancillary devices having sensor modules. When the user clicks on theindicator 750 of one of the ancillary devices or hovers her mouse overthe indicator 750, the control system 101 displays additionalinformation about the corresponding ancillary device, such as theinformation in the table 500 or graph 600, e.g. identifying informationand remaining lifetime. The indicators 750 are color coded to indicatethe current status, e.g., green for good, yellow for short remaininglifetime, and red for fault.

In one form, the control system 101 utilizes additional information toestimate or predict the remaining lifetime of ancillary devices. Withreference to FIG. 4, a monitoring apparatus 400 is provided that issimilar in many respects to the monitoring apparatus 10 discussed aboveand contains many of the same components such as the control system 101,computer 107, wireless communication hub 104, cloud-based computingsystem 105, and sensor modules 112, 122, 132, 142. The monitoringapparatus 400 further includes a cloud-based computing system 105 fromwhich additional data is transmitted to the control system 101. Exampledata includes the state of the belt, e.g. running or stopped, the speedof the belt, the weight of the material being conveyed, and weatherconditions. The weather conditions and other environmental factors canbe determined based on environmental sensors, such as rain detectors,temperature sensors, and humidity sensors located on or near theconveyor system 100, 100A. Alternatively or additionally, environmentalinformation is retrieved by the control system 101 from the internetbased on the location of the conveyor system 100, 100A. The controlsystem 101 alters the values to which the measured data is comparedbased on the additional information from the system 105. For example,the control system 101 would expect the scraper 120 and idler rollers130 to move more when the belt 102 is moving faster. As another example,the control system 101 would additionally expect the impact bed 110 tomove more when a heavier payload is being loaded onto the belt.

In some forms, the cloud based-computing system 105 includes a memorystoring a future schedule for the conveyor system 100. The schedulecontains hours of operation, speed of operation, and weight of materialfor the conveyor system 100. The control system 101 calculates theestimated remaining lifetime of one or more of the ancillary devicesbased on the scheduled workload of the conveyor system.

In addition to identifying wear as described above, the monitoringapparatus 400 utilizes data from the sensor modules 112, 122, 132, 142to identify abnormal trends. For example, data from an accelerometer ofthe sensor module 142 measures movement of the conveyor belt tracker 140and compares the movement to historical data and/or stored thresholds todetermine how often the belt 102 is currently being corrected comparesto an expected frequency of correction. A heightened frequency ofcorrections by the conveyor belt tracker 140 indicates that something iscausing the conveyor belt 102 to creep or pull in one lateral direction.The control system 101 alerts the user either via the computer 107 orthe smartphone 106. Maintenance can then be performed on the conveyorsystem 100 to identify and correct the cause of the pulling before thepulling causes premature wearing of the belt 102 and/or conveyor belttracker 140.

With reference to FIGS. 8-10, the control system 101 may providecommunications in the form of email alerts 800, 900 or text alerts 1000from the control system 101 to a user. In some forms, such as in FIG. 9,the email alerts 800, 900 or text alerts 1000 are sent out periodicallyto convey operating information. For example, graphs 960 of email alert900 indicate the amount of use each of a plurality of belts 102 haveexperienced over a predetermined timeframe. The communications may alsoinclude maintenance information, such as the amount of faults identifiedby the sensor modules and/or the number of ancillary devices to berepaired or replaced. In still further examples, the informationprovided includes the table 500 or chart 600 illustrating the currentremaining lifetime of a plurality of devices.

The control system 101 may transmit an email alert 800 or text alert1000 when an ancillary device fails or reaches a predetermined level ofremaining lifetime. For example, the control system 101 may predict thelifetimes for several devices as described above and emails or textsmaintenance personnel one week before an expected failure. Further, thecontrol system 101 may email or text a manager or overseer when a faultoccurs so that the conveyor system 100, 100A can be shutdown to avoidadditional damage.

FIGS. 13A-13C illustrate a sensor module 1305 having a sensor circuit1302 inside of a housing 1304 configured to couple to a base member of aconveyor belt cleaner 120, such as a support pole 1306. The sensormodule 1305 operates in a manner similar in many respects to the sensormodule 122 discussed above and the sensor circuit 1302 is similar to thesensor circuit 1800. The sensor module 1305 includes a housing 1304having a generally annular shape with an outward extending projectionwhich houses the sensor circuit 1302. The housing 1304 has a centralopening 1307 and an annular sleeve portion 1381 extending around thecentral opening 1307 configured to receive an end portion 1306E of thesupport pole 1306. In one form, the sleeve portion 1381 includes a slit1311 extending the entire length of the sleeve portion 1381. The sleeveportion 1381 of the housing 1304 can deflect because of the slit 1311 tofit snugly over different sized support poles 1306. In one form, thehousing 1304 permits access to the interior of the support pole 1306,such as through the central opening 1307, so that the interior of thesupport pole 1306 may be cleaned.

In one form, the sensor module 1305 is mounted at the end portion 1306Eof the support pole 1306. In another form, the sensor module 1305 isslid farther onto the support pole 1306. The position of the sensormodule 1305 along the support pole 1306 can effect the movement of thesensor module 1305 and the associated data provided by the sensor module1305. For example, the distal end portion 1306E of the support pole 1306can have a larger amplitude of movement than a portion of the supportpole 1306 closer to the associated mount connecting the support pole1306 to the conveyor frame 103. The harmonics of the support pole 1306may also impact the movement of the sensor module 1305. If the sensormodule 1305 is positioned proximate a harmonic node of the support pole1306, which is a position on the structure where vibration is minimized,the sensor module 1305 will experience less vibration than a sensormodule 1305 spaced from the harmonic nodes.

In one form, the housing 1304 includes a coupling assembly 1382configured to fix the sensor module 1305 to the support pole 1306. Inone form, the coupling assembly 1382 includes a fastener such as a bolt1318 configured to extend through bolt holes 1308A of the housing 1304and bolt holes 1308B of the support pole 1306. The coupling assembly1382 may also include a nut 1319 that engages a threaded shank of thebolt 1318. Tightening of the nut 1319 onto the bolt 1318 clamps thesleeve portion 1381 around the support pole 1306, reduces the width ofthe slit 1311, and fixes the sensor module 1305 to the support pole1306. This clamps the housing 1304 on the support pole 1306 and resiststurning of the housing 1304 about the support pole 1306 and axialmovement of the housing 1304 along the length of the support pole 1306.In another form, at least one of the holes 1308A, 1308B is threaded soas to threadingly engage the bolt 1318.

In one form, the housing 1304 has at least one substantially flat side1304F. When the sensor module 1305 is detached from the base member1306, the sensor module 1305 may be positioned on the substantially flatside 1304F thereof to reduce instances of rolling away or rolling off ofthe surface on which the sensor module 1305 is resting.

With reference to FIG. 13B, the sensor circuit 1302 includes acommunication module, and, in some embodiments, a processor. The sensormodule 1305 further includes a power source, such as batteries 1309.Alternatively or additionally, the power source can be a power cable,such as the cable 1409 in FIG. 14. In some forms, the batteries 1309 arekept in a separate compartment of the housing 1304 than the compartmentused to house the sensor circuit 1302 and other electronic components.This separation protects the electronics during movement of thebatteries, overheating of the batteries, or rupture of the batteries. Inone form, the sensor circuit 1302 of the sensor module 1305 includeswireless communication circuitry including an antenna located outside ofthe support pole 1306 to reduce interference in the wireless connection.

In some forms, the sensor module 1305 includes an indicator 1301configured to display one or more conditions of the sensor module 1305.Example conditions to be displayed include battery life, signal strengthor connectivity, and calibration. The sensor module 1305 may include amanual input, such as a button 1303. The button 1303 may be used tocontrol one or more functions of the sensor module 1305, such asresetting the wireless connection, resetting one or more sensors of thesensor module 1305, and displaying monitored conditions using theindicators 1301.

The sensor module 1305 may be configured for particular applications.For example, if the sensor module 1305 is to be installed outdoors, thehousing 1304 may have a bright color such as white to reduce heating ofthe sensor module 1305 by sunlight. The housing 1304 is formed of arigid material to reduce the risk of breaking in the harsh environmentsof the conveyor systems 100, 100A. Exemplary materials include rigidcomposites, metal alloys, metals, and/or plastics. The housing 1304 maybe a thick-walled structure to provide robustness. One or more portionsof the housing 1304 may be sealed to resist ingress of materials. In apreferred form, the housing 1304 has an ingress protection (“IP”) ratingof at least 54 (dust rating of 5, water rating of 4). In a morepreferred from, the housing 1304 has an IP66 rating.

With reference to FIG. 15, a sensor module 1505 is provided that issimilar in many respects to the sensor module 1405 discussed above. Onedifference between the sensor modules 1405, 1505 is that the sensormodule 1505 includes a housing 1504 that extends at least partially intoan opening 13060 the support pole 1306. The housing 1504 includes afirst portion or plug portion 1507 sized and configured to fit into theopening 13060 of the support pole 1306 and form a plug-fit therewith.The housing 1504 further includes a second portion or flange plateportion 1508 that extends radially beyond the outer surface of the plugportion 1507 such that the flange portion 1508 forms a stop duringinsertion, preventing the sensor module 1505 from being fully insertedinto the support pole 1306.

Inserting the insertion portion 1507 of the housing 1504 into thesupport pole 1306 reduces the space taken up by the assembly as well asprovides additional protection for the portion of the sensor module 1505inside the support pole 1306. The sensor module 1505 includes a sensorcircuit similar to the sensor circuit 1800 and includes similarcomponents, e.g., sensor(s), power sources, antennae, processor(s),etc., and thus can be used as the sensor modules 112, 122, 132, and 142described above. As with the sensor module 122, in one form the antennaof the sensor module 1505 is positioned outside of the support pole 1306to reduce interference therewith.

FIGS. 20A-20B illustrate a portion of a belt cleaner 2020 that includesa support pole 2006 and mounts 2069 for resiliently urging a scraperblade of the belt cleaner 2020 against a conveyor belt. Each mount 2069includes a tension bracket 2070 and a sensor module 2005. The tensionbracket 2070 is coupled to the support pole 2006 by a set screw or bolt2081 such that rotation of the support pole 2006 about a central,longitudinal axis 2006A of the support pole 2006 causes the tensionbracket 2070 to rotate.

The tension bracket 2070 includes a first portion, such as a sleeveportion 2071, configured to fit over an end of the support pole 2006 anda second portion, such as a wing portion 2072, extending radiallytherefrom. The bolt 2081 extends through the annular portion 2071. Insome forms, the support pole 2006 and the sleeve portion 2071 have aslot and key engagement to restrict rotation of the tension bracket 2070relative to the support pole 2006.

The wing portion 2072 includes an opening such as a slot 2074. Eachmount 2069 further includes a bolt 2082 extending through the aperture2074 and a spring 2001 extending along a portion of the bolt 2082. Thespring 2001 engages the wing portion 2072 to apply a biasing forceagainst the tension bracket 2070 and impart a torque on the support pole2006. In one form, the mount 2069 includes a stop 2083, such as a nutengaged with the bolt 2082 and a washer, limiting the distance which thetension bracket 2070 can turn about the axis 2006A. The bolt 2082further includes attachment structure 2084 configured to couple to theconveyor frame 103.

The sensor module 2005 is mounted to the tension bracket 2070. Mountingthe sensor module 2005 on a critical component of the belt cleaner 2020,such as the tension bracket 2070, reduces the likelihood of the sensormodule 2005 being inadvertently left off of the belt cleaner 2020 aftermaintenance. Turning to FIG. 20B, the tension bracket 2070 includes awall 2079 defining a recess 2073. The sensor module 2005 includes ahousing 2004 having a base portion 2011 shaped and sized to be receivedwithin the recess 2073. The housing 2004 further includes an enlarged,upper portion 2007 having a flange 2007 configured to rest on top of thewall 2079. Fasteners such as screws or bolts 2008 extend through theflange 2007 into the wall 2079 to releasably secure the sensor module2005 to the tension bracket 2070. Other approaches may be used such asstraps or welds.

The sensor module 2005 is substantially similar to the sensor modules122, 1305, and 1405 described above. The housing 2004 includes aninternal cavity housing a sensor circuit similar to the sensor circuit1800. The sensor circuit includes a sensor, wireless communicationcircuitry, and one or more sensors, such as a gyroscope and anaccelerometer. The processor receives data from the sensors andtransmits the received data via the wireless communication circuitry asdescribed above. The sensor module 2005 may also include a power source.In one form, the power source is one or more batteries. The batteriesare positioned in the housing 2004. In some forms, the batteries are ina separate cavity from the sensor circuit.

In operation, the accelerometer and/or gyroscope measures rotation ofthe tension bracket 2070 about the axis 2006A. From this rotation, aprocessor, such as a processor of the control system 101, determines thestatus of the belt cleaner 2020 and the conveyor system 100. Forexample, the orientation of the tension bracket 2070 can be used todetermine the state of wear on the scraper blades as described above.

Unlike the sensor modules 122, 1305, 1405 described above, the sensormodule 2005 may not extend past the end of the support pole 2006. Thisshortens the overall length of the belt cleaner assembly 2020. Movingthe sensor module 2005 from the end of the support pole 2006 may alsoprotect the sensor module 2005 from being impacted when something hitsthe end of the support pole 2006. In one form, the sensor module 2005does not block or restrict access to the end of the support pole 2006and the interior thereof.

In some forms, an existing belt cleaner is retrofitted with the sensormodule 2005. The existing tension bracket is replaced with a tensionbracket 2070 having the sensor module 2005. The support pole 2006 doesnot need to be replaced or modified, as the sleeve portion 2071 isconfigured to couple to existing support poles 2006.

With reference to FIG. 20B, in one form the tension of the belt cleaner2020 may be measured by a distance between portions 2091 and 2092 of asensor associated with the sensor module 2005. The sensor portions 2091and 2092 are positioned proximate opposite ends of the spring 2001. Thedistance between the sensor portions 2091 and 2092 is detected, as thelength of the spring 2001 may be used to calculate the force beingexerted thereby. In some forms, the sensor portions 2901 and 2902 arepositioned in the stop 2083 and the bolt 2082 respectively. The sensorportion 2091 may be a sensing component and the sensor portion 2092 maybe a sensed component. In some forms, the sensed portion 2092 includes apermanent or electric magnet and the sensing portion 2091 includes asensor configured to detect the magnetic field created by the sensedportion 2092. The strength of the magnetic field detected corresponds tothe distance therebetween.

In some forms, the sensor module 2005 includes an anti-tampering sensoror switch. The anti-tampering switch is configured to detect when thesensor module 2005 is removed from the tension bracket 2070. When thesensor module 2005 is removed, the processor of the sensor modules 2005operates the wireless communication circuitry thereof to transmit analert to the central control system 101 and/or a user device. In oneembodiment, the anti-tampering sensor or switch is a magnetometer, areed switch, or a mechanical switch that is operated when the sensormodule 2005 is removed from the tension bracket 2070.

Alternatively or additionally, the cloud computing system 105 identifiestampering using the sensor data from the sensor module 2005. Forexample, a large spike in acceleration followed by data inconsistentwith expected acceleration values indicates that the sensor module 2005was knocked off of the belt cleaner 2020. The cloud computing system 105transmits an alert to the central control system 101 and stopsprocessing data from the tampered with sensor module 2005 until a userinput indicates that the sensor module 2005 has been reinstalled on thebelt cleaner 2020.

The sensor module 2005 is coupled to a belt cleaner 2020. In other formsthe sensor module 2005 can be coupled to other ancillary devices havinga similar recess 2073.

While the support poles in FIGS. 2A-2B, 13A-15, and 20A-20B are shown asbeing cylindrical, it is understood that differently shaped supportpoles can be utilized by altering the shape of the housings 1304, 1504,125 of the sensor modules 1305, 1505, 122. For example, the housings1304, 1504, 125 can be shaped and configured to couple to square tubing,flat iron, or angle iron base members.

Regarding FIGS. 17A-17C, a method is provided for monitoring thecondition of the belt 102 of the conveyor system 100, 100A at afacility. A user opens the conveyor monitoring application 1700 on thesmartphone 106 or other mobile computing device such as a tabletcomputer. The tablet or smartphone 106 includes a camera. The user theninputs his location in the facility, such as an identification number ofthe conveyor belt 102 being inspected. In one approach, the user inputsthe identifying information of the location and/or conveyor belt 102 byscanning a bar code, RFID tag, or QR code 1701 mounted on or near theconveyor system 100 with the smartphone 106 as shown in FIG. 17B.

Turning to FIG. 17C, the user takes one or more pictures, and/or recordsa video, of the outer surface 1020 of the return run of the belt 102.The picture and/or video is then transmitted by the smartphone 106 tothe cloud-based computing system 105 and/or the control system 101. Aprocessor of the control system 101 compares the photograph or video tostored sample images to identify signs of wear in the belt 102. In someforms, the processor estimates the remaining lifespan of the belt basedon the identified signs of wear and transmits displays the estimatesusing the computer 107 discussed above and/or by transmitting theestimate to the smartphone 106. Alternatively or additionally, thecontrol system 101 compares the signs of wear to a stored maximum andalerts one or more users if the belt 102 exceeds the threshold amount ofwear. The pictures or videos can also be used to identify carryback onthe return side of the belt. Carryback is material that remains stuck tothe belt 102, and thus is carried by the belt 102 along the return sideof the conveyor belt to the beginning of top run 201 (see, FIG. 1C).

In some forms, the pictures and/or videos of a conveyor belt are storedin memory and/or transmitted, such as by email or multimedia message, toa remote inspector such that the remote inspector can determine thecondition of the belt without physically going to the location of thebelt. In some forms, the remote inspector assigns a numerical score tothe belt based on the condition and/or amount of carryback. The pictureand/or video of the belt is stored in a database along with thecorresponding score. Future pictures and/or videos of conveyor belts arecompared to those stored in the database by the central control system101 to approximate the score. Overtime, the database grows bigger andthus the approximations grow more accurate as there are more sampleswith which to compare.

FIG. 23 illustrates a system 2300 for monitoring the condition of aconveyor component 2340 that is similar in many respects to the systems10, 400 discussed above. The conveyor component 2340 is one of theancillary devices described above, such as a belt cleaner, idler roller,belt tracker, or impact bed. A sensor 2308 is configured to detect oneor more characteristics of the conveyor component 2340. In one form, thesensor 2308 includes an accelerometer mounted on or near the conveyorcomponent 2340 so as to detect vibration and/or movement thereof. Forexample, the sensor 2308 may include an accelerometer mounted on thesupport pole of a belt cleaner with sensor 2308 being configured todetect impacts between the one or more scraping blades of the beltcleaner and imperfections, irregularities, or interruptions along thesurface of a conveyor belt such as a splice of the conveyor belt.

The sensor 2308 may include a microphone configured to detect the soundproduced by an ancillary device. Changes in the sound produced by theancillary device may indicate a change in one or more characteristics ofthe ancillary device. For example, the microphone may detect chatterfrom a scraper blade or the sound of a failed bearing in an idlerroller. As another example, the microphone may detect the change insound of material traveling down a chute which occurs as the chute fillswith conveyed product.

The sensor 2308 outputs data representing the measured characteristicsto a controller or processor circuitry 2302. In one embodiment, thesensor 2308 and the processor circuitry 2302 are components of a sensormodule like those discussed above. In another embodiment, the sensor2308 is associated with the conveyor component 2340, and the processorcircuitry 2302 is included with a separate device in communication withthe sensor 2308.

The processor circuitry 2302 includes a memory 2304 and a processor2322. The memory 2304 may store data from the sensor 2308 representativeof one or more characteristics of the conveyor component 2340. Theprocessor 2322 is configured to perform operations on data from thesensor 2308. The operations include a step 2320 of processing the datato determine one or more characteristics of the conveyor component 2340and a step 2321 of comparing the one or more characteristics to one ormore thresholds. In some forms, the threshold values are uploaded to theprocessor circuitry 2302 and stored in the memory 2304, such as duringmanufacturing, setup, or installation. In alternative forms, thethreshold values are calculated by the processor circuitry 2302 based onmeasured parameters and/or historical sensor data.

The step 2321 of comparing the one or more characteristics to one ormore thresholds may include determining whether a characteristic isabove a threshold, below a threshold, or outside of a range betweenupper and lower thresholds. If the one or more characteristics exceedsthe threshold, the processor circuitry 2302 utilizes communicationcircuitry 2311, such as a radio transceiver 2310 and/or a Bluetoothtransceiver 2312, to output a signal to a remote computing device suchas the cloud-based computing system 105. The radio transceiver 2310utilizes radio communication to communicate over the internet with thecloud-based computing system 105. The radio transceiver 2310 may connectto the internet using Wi-Fi or cellular communication as describedabove. The Bluetooth transceiver 2312 is a short range wirelesstransmitter or transceiver, such as a Bluetooth® or BLE transceiver. TheBluetooth transceiver 2312 communicates with nearby wireless devices,such as a mobile device 106.

In some forms, the data output by the communication circuitry 2311 isencrypted or secured. In one form, the system 2300 utilizes highlysecure data transmission, such as Transport Layer Security 1.2 (TLS1.2).

The cloud-based computing system 105 stores historical data from thesensor 2308. The cloud-based computing system 105 processes 2322 thedata to identify trends. The trends are used to predict properties suchas the remaining operating lifetime of the conveyor component 2340. Auser can access the information stored on the cloud-based computingsystem 105 through a user interface of the computer 107. In oneembodiment, the computer 107 provides data from the cloud-basedcomputing system 105 to the user via a website displayed on one or morescreens of the computer 107. In another embodiment, the computer 107receives messages from the cloud-based computing system 105, such asthrough an email client. In still further examples, the computer 107includes software that facilitates communication with the informationstored on the cloud-based computing system 105. Using the computer 107,a user can see both the raw data from the sensor 2308 as well as datacalculated from the raw data. The calculated data may be, for example,predicted remaining lifetime of the component 2340 and/or instances ofreadings exceeding the threshold. In some forms, the computer 107receives inputs from the user to order parts for the conveyor component2340 and/or to schedule maintenance on the conveyor component 2340.

The cloud-based computing system 105 stores data from sensor modules2308 on a plurality of conveyor components 2340. For example, sensordata from the plurality of components 2340 associated with the sameconveyor belt can be used to identify which component 2340 needs to beadjusted. As an example, if the cloud-based computing system 105 knowsthe belt speed and the distance between upstream and downstream beltcleaners with sensor modules 2308, the cloud-based computing system 105may determine a timeframe to expect an impact of a splice against thedownstream belt cleaner after the splice has impacted the upstream beltcleaner. If the impact of the splice against the downstream belt cleaneris sufficiently greater than the impact of the splice against theupstream belt cleaner, the downstream belt cleaner may be over-tensionedand the cloud-based computing system 105 can direct a maintenance workerto adjust the downstream belt cleaner.

Further, the data from sensor modules 2308 from the conveyor componentsmay be processed 2322 together to identify larger trends. For example,sensor data from a plurality of components 2340 associated with the sameconveyor belt can be used to identify faults in the conveyor belt, suchas a faulty splice, a tear, or a dirty belt. Further, the data from theplurality of components 2340 is also used to generate predictive ratesof wear in the components 2340 and provide more accurate remainingoperating lifetime predictions.

The mobile device 106 serves as a user interface through which a user2331 can access data from the processor circuitry 2302. The dataincludes status information 2324 regarding the conveyor component 2340.In some forms, the data further includes recommended actions 2323. Forexample, if in processing 2320 the raw data from the sensor 2308, theprocessor unit 2302 determines that the conveyor component 2340 requiresmaintenance, the recommended action information 2323 conveys a suggestedmaintenance action for the user 2331 to take. In one illustrativeexample, the processor unit 2302 processes accelerometer data fromsensor 2308 to determine whether the tension of the conveyor component2340 (e.g. a belt cleaner) is between stored thresholds. If not, theprocessor circuit 2302 outputs to the mobile device 106 a suggestion forthe user to tighten or loosen the belt cleaner 2340 to adjust thetension and get the tension of belt cleaner between the set thresholds.

In some forms, the conveyor component 2340 includes an automatedadjuster 2330. In examples in which the conveyor component 2340 is abelt cleaner, the automated adjuster 2330 is an actuator for adjustingthe scraper blades relative to the belt. When the processor 2322 detectsthat the tension of the belt cleaner is not within the desired range, asdescribed above, the processor unit 2302 may operate the automatedadjuster 2330 to adjust the tension of the belt cleaner. The conveyorcomponent 2340 may include other ancillary devices such as an impactbed, a belt tracker, and a feed chute.

The operation of one conveyor component 2340 may affect other conveyorcomponents 2340. For example, if the conveyor component 2340 is a beltcleaner, the processor unit 2302 may determine the associated conveyorbelt is damaged based on data from the sensor 2308 of the conveyorcomponent 2330. The processor unit 2302 may then operate the automatedadjuster 2330 of other belt cleaners on the belt to cause the beltcleaners to move the scraper blades of the belt cleaners away from thedamaged belt. In another embodiment, the cloud-based computing system105 sends control signals to the automated adjuster 2330 and may controloperation of the automated adjuster 2330 on one conveyor component 2340and other conveyor components 2340 in response to adjustments to the oneconveyor component 2340.

As another example, if the conveyor component 2340 is a belt cleaner,the processor unit 2302 may determine the associated conveyor belt isdamaged based on data from the sensor 2308 of the conveyor component2340. The processor unit 2302 may operate the automated adjusters 2330of other conveyor components 2340 to stop conveying of material. Forexample, the processor unit 2302 may close a feed chute that suppliesmaterial onto the belt and/or stop operation of one or more conveyorbelts such as the belt being cleaned by the conveyor component 2340, anupstream conveyor belt, and/or a downstream conveyor belt.

FIGS. 24A-24B illustrate a sensor module 2405 configured to detect oneor more operating characteristics of an ancillary device of a conveyorsystem. The sensor module 2405 is similar in many respects to the sensormodule 1305 discussed above. The sensor module 2405 has a housing 2404configured to detachably couple to a conveyor system. The housing 2404has a through opening 2407 for receiving a portion of the ancillarydevice. In one embodiment, the opening 2407 is circular for coupling toa cylindrical support member, such as the support pole 1306 discussedabove.

The housing 2404 encloses a sensor circuit similar to the sensorcircuits described above. The sensor circuit is covered by a face plate2406. The face plate 2406 is coupled to the sensor module 2405 by aplurality of screws 2409. The face plate 2408 includes a user interface2401 communicatively coupled to the sensor circuit. The user interface2401 has a plurality of user inputs, such as buttons 2410, 2412, 2414(see FIG. 24B) and a plurality of outputs, such as status lights 2420,2421, 2422, 2423, 2424, 2425, 2426.

In operation, the sensor module 2405 is communicatively coupled to amobile device, such as a smartphone or tablet computer, during setupusing a short range wireless communication protocol. The pairing button2410 places the sensor module 2405 in a pairing mode such that thewireless connection can be established. In one form, the short rangewireless communication protocol utilized is Bluetooth® or BLE. Thepairing button 2410 causes the sensor module 2405 to output a pairingsignal that can be detected by a mobile device to pair the devices.

A pairing indicator 2420 outputs information to the user during thepairing process. For example, holding the pairing button 2410 causes thesensor module 2405 to temporarily enter a pairing state in which apairing signal is transmitted. While in the pairing state, the pairingindicator 2420 blinks to indicate to the user that the sensor module2405 is outputting the pairing signal. Additionally or alternatively,the pairing indicator 2420 indicates whether or not a wirelessconnection is formed. For example, the pairing indicator 2420 may beilluminated when the sensor module 2405 is wirelessly paired to at leastone mobile device.

The connection indicator 2421 indicates whether the connection betweenthe sensor module 2405 and the mobile device is secure. For example,after a mobile device pairs to the sensor module 2405, the user mustlogin on their mobile device. The connection indicator 2421 illuminatesor blinks when the login has been confirmed and the transmission of databetween the sensor module 2405 and the mobile device is initiated.

The sensor module 2405 connects to the internet using WiFi or cellularnetwork communication and includes a WiFi indicator 2423 and a cellularindicator 2425. The WiFi indicator 2423 indicates the status of a WiFiinternet connection. In one form, the WiFi indicator 2423 is a firstcolor, such as green, when a WiFi connection to a local wireless networkand the internet is established. The WiFi indicator 2423 is a secondcolor, such as red, when there is no WiFi connection. In some forms, theWiFi indicator 2423 is a third color, such as yellow, when connected tothe local wireless network (e.g., a wireless router or wireless modem)but not to the internet. In another embodiment, different types ofillumination are used instead of different colors. For example, the WiFiindicator is not illuminated when no WiFi connection exists, isilluminated when an internet connection exists, and blinks whenconnected to a router or modem but not the internet.

The cellular indicator 2425 indicates the status of a cellular networkconnection, such as a LTE CAT-M1, NB-IoT, or GSM connection as describedabove. The cellular indicator 2425 operates in substantially the samemanner as the WiFi indicator 2423. A first state, such as a first coloror continuous illumination, indicates that the sensor module 2405 isconnected to a cellular network and the internet. A second state, suchas a second color or no illumination, indicates a lack of cellularnetwork connection. A third state, such as a third color or intermittentillumination, indicates connection to a cellular network gateway, suchas a cellular tower, but no internet connection.

The housing 2404 includes one or more batteries, similar to thebatteries described in the sensor modules above. The housing 2404includes a removable battery plate 2408 which covers the batterycompartment. Removing the battery plate 2408 provides access to thepower source compartment of the housing 2404 to allow the battery orbatteries to be removed and replaced. The battery or batteries mayinclude, for example, a single-use battery such as a battery havinglithium-thionyl chloride cells, a rechargeable battery. The battery orbattery may store energy received from solar cells.

Regarding FIG. 24A, the battery indicator 2424 indicates the charge ofthe battery. The battery indicator 2424 includes lights to show anapproximate percent of charge remaining in the battery. For example, allfour lights being illuminated indicates approximately 100% charge, threelights being illuminated indicates approximately 75% charge, two lightsbeing illuminated indicates approximately 50% charge, and one lightbeing illuminated indicates approximately 25% charge. In some forms, atleast one of the lights of the battery indicator 2424 is operable toilluminate in at least two colors. Illuminating a single light in asecond color indicates a critically low battery charge, such as lessthan 10%. In alternative embodiments, a different state of illuminationis used instead of a different color, such as a single blinking light toindicate less than 10% charge remaining.

Alternatively or additionally to the battery, the sensor module 2405includes a wired connection to a power source. A wired power sourceindicator 2426 indicates connection to the power source such as anelectrical mains. The power source indicator 2626 is illuminated whenconnected to the power source and off when not connected. In some forms,the wired power source is detachable to charge the battery or batteries,such as a charging cable. Some chargers include one or more additionalbatteries. For example, in one form the sensor module 2405 includes aport for forming a wired connection to the mobile device used duringsetup. The port may be a USB port by which the sensor module 2405 andmobile device can be connected via a USB cord. By this connection, themobile device communicates data and charges the battery or batteries ofthe sensor module 2405.

The sensor module 2405 further includes additional status indicators2422. The status indicators 2422 include lights used to indicate otherstatus information. In some forms, the status indicators 2422 aremulticolor LEDs, such as red, yellow, and green LEDs. Exemplary statusinformation includes faults with the sensor module 2405, such as afrozen processor or damaged sensor.

To save battery life, the sensor module 2405 includes a status input2412. Pressing the status input causes the outputs 2420, 2421, 2422,2423, 2424, 2425, 2426 to illuminate to indicate statuses as describedabove. After the status input 2412 is released, the indicators 2420,2421, 2422, 2423, 2424, 2425, 2426 turn off to save energy. In someforms, there is a time delay after the status input 2412 is releasedbefore the indicators turn off.

Regarding FIG. 24B, the power button 2414 is on the back side of thesensor module 2405 for turning the sensor module 2405 on and off. Byhaving the power button 2414 on the back side of the sensor module 2405,a maintenance worker is less likely to accidently press the power button2414 believing the power button 2414 is the pairing button 2410 or thestatus indicator button 2412.

FIG. 25 illustrates a method 2500 of setting up a conveyor system havingsensor modules, such as the sensor modules described herein. The user,such as an installer or maintenance worker, sets up the conveyor systemsensor modules 2522 using a mobile device 106.

As an initial step, a site ontology is generated and loaded 2501 ontothe system, such as the cloud-based computing system 105. The ontologyillustrates the overall layout of the conveyor system, including thelocation and identity of the ancillary devices. The identity of eachancillary device may include the brand and/or model of the ancillarydevice as well as the identify of one or more components of theancillary device. For example, the identify of a belt cleaner mayinclude the brand and model of the belt cleaner as well as the brand andmodel of the scraper blade of the belt cleaner. The user is authorized2502 to view the ontology to aid in the installation and setup of theancillary devices and sensor modules.

During setup, the user may install 2503 a new blade on the belt cleaner120 and properly tension the belt cleaner 120. One of the sensor modules2522 is installed 2504 on the belt cleaner 120 in a position such thatthe sensor module 2522 monitors one or more operating characteristics ofthe belt cleaner 120.

The installed sensor module 2522 is then turned 2505 on. The userobserves the indicators, such as the indicators 2420, 2421, 2422, 2423,2424, 2425, 2426 described above, to check the status of the sensormodule 2522. A short range wireless connection is established 2506between the sensor module 2522 and the mobile device 106. As describedabove, exemplary short range wireless connections include Bluetooth® orBLE connections. The user provides login information to the userinterface of the mobile device 106 that is communicated to the sensormodule 2522. The login information may include information required topermit the user to setup the sensor module 2522 as well as informationrequired to access a wireless network. The sensor module 2522 uses theinformation to establish 2507 an internet connection. The internetconnection communicatively couples the sensor module 2522 to thecloud-based computing system 105. The user inputs validating orauthenticating information, such as a password and/or ID to form asecure connection between the sensor module 2522 and the cloud-basedcomputing system 105.

Information is uploaded to the cloud-based computing system 105 to link2508 the sensor module 2522 with the specific conveyor system and thespecific location within the conveyor system. In some forms, linking2508 involves editing 2509 the ontology. Each sensor module 2522 has aunique identifier, such as an ID number, allowing it to be identifiedfor the purpose of linking 2508. In some forms, the identifier isprinted on the body of the sensor module 2522, such as with a scannablecode. Alternatively or additionally, the identifier is stored in thememory of the sensor module 2522 and accessed by the mobile device 106after the connection is established 2506.

With the connection to the cloud-based computing system 105 formed, thesensor module 2522 starts recording 2510 data as described in themethods above. The recorded data is transmitted to the cloud-basedcomputing system 105 via the internet connection. The cloud-basedcomputing system 105 stores and processes the data.

The user repeats steps 2503-2509 for each sensor module 2522 of theconveyor system such that every sensor module 2522 is linked to aspecific location in the ontology and is communicatively coupled to thecloud-based computing system 105.

During maintenance, the sensor modules 2522 can be relinked to locationsin the conveyor system ontology by following steps similar to thosedescribed above. The user removes one or more sensor modules 2522 fromone or more conveyor accessories to service the sensor modules 2522, forexample to replace or recharge the batteries. As the user reinstalls thesensor modules 2522 on the conveyor accessories, a communication link isestablished 2506 between the mobile device 106 and one of the sensormodules 2522. In one embodiment, the linking involves a Bluetoothpairing procedure between the mobile device 106 and the sensor module2522.

When the linked sensor module 2522 is installed to a conveyor accessory,the user indicates the location of the sensor module 2522 in theconveyor system ontology using the mobile device 106. In one embodiment,the user utilizes a touch screen of the mobile device 106 to indicatethe location of the sensor module 2522 in the conveyor system ontology.The mobile device 106 communicates information regarding the location toat least one of the cloud-based computing system 105 and the mobiledevice 106.

The user repeats the installation and linking procedure for each sensormodule 2522 as the sensor module 2522 is reinstalled. By indicating thelocation of each sensor module 2522 when the sensor module 2522 isinstalled, the user does not need to make sure each sensor module 2522is installed in the same location as before it was removed. This permitsa maintenance worker to quickly replace or recharge batteries for numberof sensor modules 2522 in confined environments such as mines.

With reference to FIG. 26, a sensor module 2600 is provided that similarto the sensor modules discussed above and is mounted to a support pole2602 of a conveyor belt cleaner 2604. The support pole 2602 may includea cylindrical side wall extending about an opening 2603 of the supportpole 2602. The sensor module 2600 is mounted to the support pole 2602outward from a mount 2606 of the conveyor belt cleaner 2604. The mount2606 has a sleeve 2608 secured to the support pole 2602 by one or morelocking fasteners 2610. The sensor module 2600 has a housing upperportion 2612 and a housing lower portion 2614 that define a throughopening 2616 for receiving the support pole 2602. The housing upperportion 2612 includes a cover 2618 that may be made of a flexiblematerial, such as an elastomer, and is used to cover fasteners 2620 (seeFIG. 27) that secure the upper housing portion 2612 and the housinglower portion 2614 in a clamped arrangement on the support pole 2602.

The housing upper and lower portions 2612, 2614 have an installation orinitial configuration that permits the housing upper and lower portions2612, 2614 to be positioned onto the support pole 2602. In oneembodiment, the initial configuration includes the housing upper andlower portions 2612, 2614 being completely separated from each other. Inanother embodiment, the housing upper and lower portions 2612, 2614 areconnected by a hinge and are spaced apart in the initial configuration.Once the housing upper and lower portions 2612, 2614 are positioned onthe support pole 2602, a user reconfigures the housing upper and lowerportions 2612, 2614 to a clamping configuration wherein the upper andlower portions 2612, 2614 clamp the support pole 2602 therebetween. Inone embodiment, the user reconfigures the housing upper and lowerportions 2612, 2614 by inserting the fasteners 2620 through openings2646 (see FIG. 27) of the housing upper and lower portions 2612, 2614and tightening down the fasteners 2620. The support pole 2602 hasdistinct vibrations caused by operation of the associated conveyor beltand mounting the sensor module 2600 to the support pole 2602 providesclear vibrations for measurement by the sensor module 2600.

In one approach, the cover 2618 is flexible and includes an end portion2626 having an opening 2622 that receives a catch 2624 of the housingupper portion 2612. The cover 2618 has an end portion 2627 opposite theend portion 2626 that is secured to the housing upper portion 2612. Toaccess the fasteners 2620, the end portion 2626 of the cover 2618 ismanipulated to disengage the end portion 2626 from the catch 2624 andmoved away from the housing upper portion 2612 in direction 2628.

The sensor module 2600 includes a user interface 2630 that may includeone or more buttons 2632. The user may press one of the buttons 2632 torequest a status of the sensor module 2600 and may press another one ofthe buttons 2632 to establish a short-range wireless link between thesensor module 2600 and a portable electronic device, such as asmartphone.

With reference to FIG. 27, the housing upper portion 2612 includessockets 2640 that receive the fasteners 2620 and the cover 2618 includesplug portions 2642 sized to fit into the sockets 2640, cover heads 2644of the fasteners 2620, and resist ingress of material into drivestructures of the fasteners 2620. The plug portions 2642 of the cover2618 also may extend around the heads 2644 and resist ingress of debrisinto the openings 2646 of the housing upper portion 2612 through whichthe fasteners 2620 extend. The housing upper portion 2612 and thehousing lower portion 2614 include clamping portions 2650, 2652 that arecurved or otherwise shaped to complement an outer surface 2654 (see FIG.26) of the support pole 2602.

The housing lower portion 2614 includes a compartment 2656 that receivesa circuit board 2658, a circuit board support 2660, and a battery 2662.The compartment 2656 includes one or more walls 2664 and a door 2666having a seal 2668 that engages the one or more walls 2664 and seals thecompartment 2656. The door 2666 includes openings 2670 for receiving,for example, fasteners 2673 operable to secure the door 2666 to thewalls 2664 and for permitting access to a power button 2672 of thesensor module 2600. The door 2666 includes protective covers 2678configured to fit into each of the openings 2670 and cover the fastener2672 or the power button 2672 therein. The door 2666 may be formed usinga two-shot process wherein a body 2676 of the door 2666 is formed usinga first injected molded material and the seal 2668 and protective covers2678 are formed in a second injection using a second injected material.In this manner, the door 2666 has a one-piece construction so that thedoor 2666 may be removed from and connected to the walls 2654 readilywithout a user misplacing the seal 2668 or the protective covers 2678.In one embodiment, the housing upper portion 2612 and the housing lowerportion 2614 including the door body 2676 are made of a rigid material,such as glass-filled nylon. The seal 2668 and the cover 2678 may be madeof a soft elastomer, as an example. The circuit board support 2660 maybe made of a rigid material such as acrylonitrile butadiene styreneplastic.

Regarding FIG. 27, the circuit board 2658 includes a processor 2680,communication circuitry 2682, one or more sensors 2684, and a memory2686. The circuit board support 2660 receives the circuit board 2658 andsecurely mounts the circuit board 2658 within the housing lower portion2614. The circuit board 2660 further includes a battery compartment 2690for receiving the battery 2662.

The one or more sensors 2682 are configured to detect one or morecharacteristics of the support pole 2602. The one or more sensors 2684may include, for example, an accelerometer, a gyroscope, or acombination thereof. The sensors 2684 may measure, for example,acceleration in a Z direction along the length of the pole 2602 (whichmay be caused by flexing of pole), acceleration in a X-axis directionperpendicular to the Z axis, acceleration in a Y-axis directionperpendicular to both the Z- and X-axes, and accelerations about one ormore of the X, Y, and Z axes. The support pole 2602 experiences highacceleration, small displacement movements caused by operation of theconveyor belt and detected by the one or more sensors 2684. The supportpole 2602 also experiences large displacement events such as a spliceimpacting the cleaner blade of the conveyor belt cleaner 2604 which arealso detected by the one or more sensors 2684.

As an example, the one or more characteristics of the support pole 2602may include the orientation of the support pole 2602. The sensors 2684may detect the orientation of the support pole 2602 relative to gravity.As the cleaner blade wears down, the support pole 2602 will turn and thesensor 2684 will detect the change in the orientation of the supportpole 2602 relative to gravity. The sensor module 2600 may communicatethe orientation of the support pole 2602 so that one or more propertiesof the cleaner blade may be predicted, such as the remaining life of thecleaner blade.

With reference to FIG. 28, the sensor module 2600 may be installed andoperated in a manner consistent with the sensor modules as discussedabove. In one embodiment, the sensor module 2600 is installed on thesupport pole 2602 and the user wirelessly connects a portable electronicdevice, such as a smartphone 2700, to the sensor module 2600. Thesmartphone 2700 may communicate 2704 information to and/or receiveinformation from the sensor module 2600. Once connected, the smartphone2700 may operate as a remote control for the sensor module 2600 andcause the sensor module 2600 to communicate 2708, 2730 information toand/or from a cloud computing system 2710 which includes a remote server2720.

For example, the smartphone 2700 may connect to the sensor module 2600via a short-range wireless protocol, such as Bluetooth, utilized by thecommunication circuitry 2682. In one approach, a user such as amaintenance worker presses a pairing button 2632A of the sensor module2600 to place the sensor module 2600 in a pairing mode and the user maypair the smartphone 2700 with the sensor module 2600. Once thesmartphone 2700 and the sensor module 2600 are paired, the user may usean application running on the smartphone 2700 to enter informationidentifying the conveyor belt cleaner 2604 to which the sensor module2600 is connected such as by using a displayed graphical user interface2702. For example, the information may include an identity of theconveyor belt system associated with the conveyor belt cleaner 2604, thelocation of the conveyor belt cleaner 2604 along the conveyor belt, themodel number of the conveyor belt cleaner 2602, and the model number ofscraper blades installed in the conveyor belt cleaner 2602. Furtherinformation can be provided via the smartphone 2700, such as theestimated tension the conveyor belt cleaner 2604 is applying to thecleaner blades, the material being handled by the conveyor belt, thematerial of the conveyor belt, and/or other information.

The smartphone 2700 communicates 2704 the information to the sensormodule 2600 and the sensor module 2600 communicates 2708 the informationto the remote server 2720, such as via a cellular network 2712 and theinternet 2718. The communication 2708 includes a globally uniqueidentifier for the sensor module 2600 so that the remote server 2720 mayassociate the received information with the sensor module 2600 thatcommunicated the information.

Because the sensor module 2600 operates as an intermediary between thesmartphone 2700 and the cellular network 2712, the smartphone 2700 doesnot have to connect to the cellular network 2712 which may be difficultin remote locations. In one embodiment, the sensor module 2600communicates with the cellular network 2712 using the 4G LTE CAT Mstandard which may provide better communication in remote areas thanconventional 3G or 4G cellular networks. In another embodiment, thesensor module 2600 communicates with a remote server 2720 via a localwireless gateway and the internet. Because the sensor module 2600operates as an intermediary between the smartphone 2700 and the localwireless gateway, the smartphone 2700 does not have to connect to thelocal wireless gateway. This may improve wireless network security forthe facility because a maintenance worker does not have to connect tothe local wireless gateway in order to setup or service the sensormodule 2600.

The cloud computing system 2710 is similar in many respects to the cloudcomputing systems discussed above and includes the remote server 2720.The remote server 2720 includes a processor 2722, a communicationinterface 2724, and a memory 2726. The memory 2726 includes a historicaldatabase 2728 that contains historical information that is used by theprocessor 2722 during operation of the conveyor belt to estimate one ormore characteristics of the cleaner blade of the conveyor belt cleaner2604 as discussed above. The historical database 2728 may includehistorical data representative of one or more characteristics of thesupport pole 2602 as the support pole 2602 vibrates with operation ofthe associated conveyor belt.

The processor 2722 of the remote server 2720 predicts at least oneproperty of the conveyor belt cleaner 2604 by comparing the at least onecharacteristic of the support pole 2602 to at least one characteristicstored in the database 2728. In one embodiment, the processor 2722monitors changes to the vibration signatures detected by the sensors2684 to identify changes in the at least one property of the cleanerblade. The signal from a given sensor 2684 monitoring vibration of thesupport pole 2602 includes a number of different frequencies and a fastFourier transform may be performed to identify which frequencies arepresent in the signal. There may be specific frequencies that are moreprominent in the data than other frequencies. These prominent orfundamental frequencies may vary over time as the conveyor beltoperates. For example, the processor 2722 may observe whether thedetected fundamental frequencies change by a number of Hz from thebaseline frequencies observed when the sensor module 2600 was initiallyinstalled on the support pole 2602. The processor 2722 may determine achange has occurred to the at least one property of the cleaner blade ifthe change in the fundamental frequencies is greater than apredetermined threshold. The processor 2722 may cause the communicationinterface 2724 to send an alert to the maintenance worker's smartphone2700.

For example, with reference to FIG. 34, a graph 3000 is provided of thefrequency domain response of signals from an accelerometer mounted to asupport pole of a conveyor belt cleaner which were obtained duringtesting. The graph 3000 illustrates how the fundamental frequencies ofthe frequency domain response change with changes in the operation ofthe associated conveyor belt system. For example, when the conveyor beltwas loaded with material and the tension of the conveyor belt cleanerwas zero or 100% of allowable tension, the measured fundamentalfrequency occurs at frequency 3002. When there was no material on theconveyor belt and the tension of the conveyor belt cleaner was 0%, thefundamental frequency occurs at frequency 3004. When there was nomaterial on the conveyor belt and the tension of the conveyor beltcleaner was 100%, the fundamental frequency occurs at frequency 3006.With this historical data stored in the database 2728, the processor2722 will be able to predict that there is no material on the belt andthe cleaner blades of the conveyor belt cleaner are subject to zeropercent tension if the fundamental frequency measured during operationof the conveyor belt occurs at frequency similar to frequency 3004. Inthis manner, the processor 2722 may predict one or more currentproperties of the conveyor belt and/or conveyor belt cleaner bladesbased on historical data of one or more characteristics of the supportpole.

As another example, the processor 2722 may predict chattering of acleaner blade of the conveyor belt cleaner 2604 by identifying adeviation of the frequency and/or amplitude of one or more fundamentalfrequencies of the acceleration of the support pole 2602 from thehistorical frequency and/or amplitude. Alternatively or additionally,the historical database 2728 may include historical data representativeof one or more characteristics of the support poles of other conveyorbelt cleaners associated with the same conveyor belt or differentconveyor belts. The processor 2722 may utilize the historical data fromthe other conveyor belt cleaners to generate one or more thresholds forthe deviation that must be met before the deviation in the frequencyand/or amplitude of the fundamental frequencies of the at least onecharacteristic of the support pole 2602 triggers an alert to be sent tothe maintenance team.

The processor 2722 may utilize data from other sources to predict the atleast one property of the cleaner blade of the conveyor belt cleaner2604. For example, the communication interface 2724 may receive positiondata from a linear actuator of the conveyor belt cleaner 2604. Theprocessor 2722 may use the position data and the sensed at least onecharacteristic of the support pole 2602 to predict whether the cleanerblade is engaged with the conveyor belt.

The database 2728 also includes a plurality of algorithms that are usedto model the physical behavior of conveyor belt cleaner 2604. One ormore of the algorithms may be used by the sensor module 2600, the remoteserver 2720, or both. For example, based on information received via thecommunication 2708 from the sensor module 2600, the remote server 2720may send a communication 2730 to the sensor module 2600 that includes atleast a portion of an algorithm, such as a complete algorithm orvariables of an algorithm, that corresponds to the type of conveyor beltcleaner 2604 to which the sensor module 2600 is mounted. For example,the processor 2722 of the remote server 2720 may select the at least aportion of an algorithm based upon, for example, the brand of theconveyor belt cleaner 2604, the model of the conveyor belt cleaner 2604,the size of the conveyor belt cleaner 2604, the model of the cleanerblades, the type of material being conveyed by the associated conveyor,and/or other information. The processor 2722 uses the at least a portionof an algorithm to perform initial processing on the data received fromthe one or more sensors 2684. The sensor module 2604 may thereby provideedge processing for the system.

Using the at least a portion of an algorithm received, the sensor module2600 may calculate one or more characteristics of the support pole 2602as the support pole 2602 vibrates during operation of the associatedconveyor belt. The at least one characteristic may include, for example,translational acceleration, rotational acceleration, position, velocity,direction of gravity, or a combination thereof. The sensor module 2600may communicate the at least one characteristic of the support pole 2602to the remote server 2720. The processor 2720 uses the at least onecharacteristic of the support pole 2602 to predict at least one propertyof a cleaner blade of the conveyor belt cleaner 2604. The at least oneproperty may include, for example, whether the cleaner blade is engagedwith the belt, the tension applied to the cleaner blade, residual bladeheight, whether the cleaner blade is chattering, and/or whether acushion of the conveyor belt cleaner blade is damaged. The remote server2720 may also use the at least one characteristic of the support pole2602 to predict at least one property of the conveyor belt associatedwith the conveyor belt cleaner 2604. The at least one property of theconveyor belt may include whether there is material present on theconveyor belt, whether the conveyor belt is running, the conveyor beltspeed, whether the conveyor belt is mistracking, or a combinationthereof.

With reference to FIG. 29, there may be some conveyor belt cleanerswherein the support pole thereof does not extend beyond the mounts ofthe conveyor belt cleaner. In these situations, a pole extender 2800 maybe used to create additional space outside the material handling path ofthe conveyor belt for mounting the sensor module 2600. The pole extender2800 includes a body 2802 having an annular wall 2804 with an outersurface 2806 that may be sized and shaped similarly to- or differentlythan the support pole to which the pole extender 2800 is connected. Theouter surface 2806 may resemble a cylinder, a rectangular prism, orother shapes and the associated sensor module 2600 is configured toclamp onto the outer surface 2806.

Regarding FIGS. 29 and 32, the pole extender 2800 includes a mountingportion 2810 having an installation or initial configuration wherein themounting portion 2810 is sized to be inserted into an opening 2812 of asupport pole 2811. This connects the pole extender 2800 to the supportpole 2811, despite the support pole 2811 having a mount 2813 at the endof the support pole 2811. The mounting portion 2810 further includes anexpanded configuration (see FIG. 33) wherein the mounting portion 2810engages an inner surface 2814 of the support pole 2811 and rigidly fixesthe pole extender 2800 to the support pole 2811.

Returning to FIG. 29, the mounting portion 2810 includes one or moredeflectable members 2820, such as arcuate walls 2822, separated by gaps2824. Each arcuate wall 2822 includes a base portion 2826 and a free endportion 2828. The mounting portion 2810 includes a spreader 2830 havinga tubular body 2832 and walls 2834 extending radially outward from thetubular body 2832. The walls 2834 include one or more cam walls 2836 andone or more anti-rotational walls 2838. The cam walls 2836 areconfigured to engage inner surfaces 2840 of the walls 2822 and urge thewalls 2822 apart. The anti-rotational walls 2838 are sized to fit intothe gaps 2824 to resist turning of the spreader 2830 as the spreader2830 urges the arcuate walls 2822 against the inner surface 2814 of thesupport pole 2811.

With reference to FIG. 30, the pole extender 2800 includes an actuator2849, such as a bolt 2850, having a head 2852 and a shank 2854 dependingfrom the head 2852. The pole extender 2800 includes a base, such as across pin 2854, that extends through a through opening 2856 of theannular wall portion 2804. The cross pin 2854 includes a through opening2856 through which the shank 2854 extends and a recess portion 2858 thatreceives the head 2852 and permits turning of the head 2852. The shank2854 includes a threaded portion 2860 engaged with threads 2862 of athrough bore 2864 of the spreader 2866. In this manner, turning of thehead 2852 in a clockwise direction causes the spreader 2866 to shift indirection 2870 toward the annular wall 2804. As the spreader 2866 shiftsin direction 2870, the cam walls 2836 engage the inner surfaces 2840 ofthe walls 2822 and urge the walls 2822 apart.

With reference to FIG. 31, the longitudinal axis 2880 of the poleextender 2800 extends through the through bore 2864 of the spreader2830. Each cam wall 2836 includes an inclined surface 2882 that extendsat an angle 2884 relative to the longitudinal axis 2880. The angle 2884may be in the range of 1 degree to 18 degrees, such as 4 degrees.

Regarding FIG. 32, the pole extender 2800 is shown connected to thesupport pole 2811 with the arcuate walls 2822 and the spreader 2830positioned in the opening 2812 of the support pole 2811. The arcuatewalls 2822 have been advanced into the opening 2812 until a shoulder2890 of the pole extender abuts an end surface 2892 of the support pole2811. The arcuate walls 2822 include arcuate walls 2822A, 2822B that arepositioned across the opening 2812 from each other. The arcuate walls2822A, 2822B are described below, although the other arcuate walls 2822will undergo a similar operation.

Initially, the arcuate walls 2822A, 2822B are positioned with outersurfaces 2894 thereof facing the inner surface 2814 of the support pole2811. The walls 2822A, 2822B have an initial distance 2898 between innersurfaces 2840 of the walls 2822A, 2822B.

With reference to FIG. 33, the user has tightened the bolt 2850, such asby using an impact wrench, which has shifted the spreader 2830 indirection 2870. The inclined surfaces 2882 of the cam walls 2836 haveurged the walls 2822A, 2822B apart which engages an outer surface 2894of the walls 2822A, 2822B with the inner surface 2814 of the supportpole 2811. In one approach, the shifting of the spreader 2830 creates adistance 2912 between the inner surfaces 2840 of the walls 2822A, 2822Bthat is to larger than the distance 2898 when the pole extender 2800 isin the initial configuration thereof. This increase in distance 2898 mayoccur because there may be radial gap spacings between the arcuate walls2822 and the inner surface 2814 of the support pole 2811 sized to permitthe pole extender 2800 to be connected to the support pole 2602.Shifting of the spreader 2830 deflects the free ends 2828 radiallyoutward into the radial gaps and into contact with the inner surface2814 of the support pole 2811.

The movement of the spreader 2830 in direction 2870 may permanentlydeform the material of the arcuate walls 2822. The deformation of thewalls 2822 against the support pole 2811 permanently fixes the poleextender 2800 to the support pole 2811. The user may then mount thesensor module 2600 to the pole extender 2800.

In one embodiment, the components of the pole extender 2800 are made ofone or more rigid, metallic materials such as steel. The rigid materialsof the pole extender 2800 and the secure fixation provided by thespreader 2830 and arcuate walls 2822 permit the pole extender 2800 tovibrate in a substantially similar manner as the support pole 2811.Thus, the sensor module 2600 may measure one or more characteristics ofthe pole extender 2800 as the pole extender vibrates with the supportpole 2811 during conveyor belt operation.

In one embodiment, the cross pin 2854 is press fit in the throughopening 2856. In another embodiment, the cross pin 2854 is welded in thethrough opening 2856. The actuator 2849 and the spreader 2830 may have anumber of configurations to translate movement of the actuator 2849 intoshifting of the spreader 2830 in direction 2870. For example, theactuator 2849 may include a nut threaded onto a shaft of the spreader2830. Turning the nut shifts the shaft and the spreader 2830 indirection 2870. In another embodiment, the actuator 2849 may be shiftedaxially without rotation to cause the spreader 2830 to shift indirection 2870.

Those skilled in the art will recognize that a wide variety ofmodifications, alterations, and combinations can be made with respect tothe above-described embodiments without departing from the spirit andscope of the invention, and that such modifications, alterations, andcombinations are to be viewed as being within the scope of the claims.For example, although method steps may be presented and described hereinin a sequential fashion, one or more of the steps shown and describedmay be omitted, repeated, performed concurrently, and/or performed in adifferent order than the order shown in the figures and/or describedherein. Further, it will be appreciated that computer-readableinstructions for facilitating the methods described above may be storedin various non-transitory computer readable mediums as is known in theart.

What is claimed is:
 1. An apparatus for monitoring a conveyor beltcleaner, the apparatus comprising: a c-shaped member having endsseparated by a gap, the ends of the c-shaped member facing one anotheracross the gap; the c-shaped member extending about an opening sized toreceive an elongate support of the conveyor belt cleaner and permit thec-shaped member to be mounted on the elongate support; a sensoroperatively mounted to the c-shaped member and configured to detect atleast one characteristic of the elongate support as the elongate supportvibrates during conveyor belt operation; communication circuitryoperatively mounted to the c-shaped member, the communication circuitryconfigured to communicate data associated with the at least onecharacteristic of the elongate support to a communication hub.
 2. Theapparatus of claim 1 wherein the c-shaped member includes an innerannular surface extending about the opening to contact an outer surfaceof the elongate support.
 3. The apparatus of claim 1 wherein thec-shaped member includes an inner surface extending about the opening,the apparatus further comprising: a clamp operable to engage the innersurface of the c-shaped member with an outer surface of the elongatesupport and secure the c-shaped member to the elongate support.
 4. Theapparatus of claim 1 wherein the at least one characteristic includes aposition of the elongate support.
 5. The apparatus of claim 1 whereinthe sensor is configured to detect a change in position of the elongatesupport.
 6. The apparatus of claim 1 wherein the sensor is configured todetect a rotary distance the elongate support travels.
 7. The apparatusof claim 1 in combination with the communication hub, the communicationhub configured to communicate with a remote computer via a wirelessnetwork.
 8. The apparatus of claim 1 further comprising a batteryoperatively connected to the sensor and the communication circuitry. 9.The apparatus of claim 1 further comprising at least one indicator. 10.The apparatus of claim 1 further comprising a temperature sensor; andwherein the communication circuitry is operable to communicate dataassociated with a temperature detected by the temperature sensor to thecommunication hub.
 11. An apparatus for monitoring a conveyor beltcleaner, the apparatus comprising: a housing; an opening of the housingsized to receive an elongate support of the conveyor belt cleaner andpermit the housing to be mounted on the elongate support; a sensor inthe housing configured to detect at least one characteristic of theelongate support as the elongate support vibrates during conveyor beltoperation; communication circuitry in the housing, the communicationcircuitry configured to communicate data associated with the at leastone characteristic of the elongate support to a communication hub;wherein the housing includes a sleeve portion extending about theopening, the sleeve portion having a pair of ends separated by a gap;and a clamping member operable to narrow the gap and clamp the sleeveportion on the elongate support.
 12. An apparatus for monitoring aconveyor belt cleaner, the apparatus comprising: a housing; an openingof the housing sized to receive an elongate support of the conveyor beltcleaner and permit the housing to be mounted on the elongate support; asensor in the housing configured to detect at least one characteristicof the elongate support as the elongate support vibrates during conveyorbelt operation; communication circuitry in the housing, thecommunication circuitry configured to communicate data associated withthe at least one characteristic of the elongate support to acommunication hub; wherein the housing comprises a compartment having atleast one wall, a door for being connected to the at least one wall andclosing the compartment, and a plurality of fasteners for securing thedoor to the at least one wall.
 13. An apparatus for monitoring aconveyor belt cleaner, the apparatus comprising: a housing; an openingof the housing sized to receive an elongate support of the conveyor beltcleaner and permit the housing to be mounted on the elongate support; asensor in the housing configured to detect at least one characteristicof the elongate support as the elongate support vibrates during conveyorbelt operation; communication circuitry in the housing, thecommunication circuitry configured to communicate data associated withthe at least one characteristic of the elongate support to acommunication hub; and wherein the data associated with the at least onecharacteristic of the elongate support is received by a remote computerconfigured to estimate a remaining lifespan of a cleaner blade of theconveyor belt cleaner.
 14. An apparatus for monitoring a conveyor beltcleaner, the apparatus comprising: a sensor module configured to bemounted on an elongate support of the conveyor belt cleaner; a clampportion of the sensor module having an inner surface to engage an outersurface of the elongate support, the clamp portion of the sensor moduleincluding a threaded member and a nut, the clamp portion configured toclamp the inner surface of the sensor module against the outer surfaceof the elongate support and secure the sensor module to the elongatesupport upon tightening of the nut and the threaded member together sothat the sensor module moves with the elongate support during conveyorbelt operation; a sensor of the sensor module configured to detect atleast one characteristic of the elongate support; and communicationcircuitry of the sensor module, the communication circuitry configuredto communicate data associated with the at least one characteristic ofthe elongate support to a communication hub.
 15. The apparatus of claim14 wherein the clamp portion of the sensor module includes a sleeveportion having an opening to receive the elongate support.
 16. Theapparatus of claim 14 wherein the at least one characteristic includes aposition of the elongate support.
 17. The apparatus of claim 14 whereinthe sensor is configured to detect a change in a position of theelongate support.
 18. The apparatus of claim 14 wherein the sensor isconfigured to detect a rotary distance the elongate support travels. 19.The apparatus of claim 14 wherein the clamp portion of the sensor moduleincludes a band for securing the sensor module to the elongate support.20. The apparatus of claim 14 in combination with the communication hub,the communication hub configured to communicate with a remote computervia a wireless network.
 21. The apparatus of claim 14 wherein the sensormodule includes a battery to provide power to the sensor and thecommunication circuitry.
 22. The apparatus of claim 14 wherein thesensor module includes a temperature sensor; and wherein thecommunication circuitry is operable to communicate data associated witha temperature detected by the temperature sensor to the communicationhub.
 23. An apparatus for monitoring a conveyor belt cleaner, theapparatus comprising: a sensor module configured to be mounted on anelongate support of the conveyor belt cleaner; a clamp portion of thesensor module configured to engage an outer surface of the elongatesupport and secure the sensor module to the elongate support so that thesensor module moves with the elongate support during conveyor beltoperation; a sensor of the sensor module configured to detect at leastone characteristic of the elongate support; communication circuitry ofthe sensor module, the communication circuitry configured to communicatedata associated with the at least one characteristic of the elongatesupport to a communication hub; and wherein the clamp portion of thesensor module includes a pair of clamping surface portions having aninitial configuration wherein the clamping surface portions permit theelongate support to be received therebetween and a clampingconfiguration wherein the clamping surface portions engage outer surfaceportions of the outer surface of the elongate support and clamp theelongate support between the clamping surface portions.
 24. Theapparatus of claim 23 wherein the clamp portion of the sensor module hasan inner surface configured to extend about the elongate support and thepair of clamping surface portions comprise a pair of inner surfaceportions of the inner surface that are across the elongate support fromeach other for clamping the elongate support therebetween in theclamping configuration.
 25. The apparatus of claim 24 wherein the innersurface is arcuate for clamping a cylindrically configured elongatesupport member.
 26. The apparatus of claim 23 wherein the clamp portionof the sensor module comprises a sleeve portion having an opening toreceive the elongate support, the sleeve portion including the pair ofclamping surface portions extending about the opening.
 27. The apparatusof claim 26 wherein the sleeve portion of the sensor module includes apair of ends separated by a gap, wherein the clamp portion includes aclamping member operable to narrow the gap.
 28. The apparatus of claim23 wherein the clamp portion of the sensor module includes a C-shapedmember comprising the pair of clamping surface portions.
 29. Theapparatus of claim 23 wherein the sensor is configured to detect achange in a position of the elongate support.
 30. The apparatus of claim23 wherein the sensor is configured to detect a rotary distance theelongate support travels.
 31. The apparatus of claim 23 wherein theclamp portion of the sensor module includes a band for securing thesensor module to the elongate support.
 32. The apparatus of claim 23 incombination with the communication hub, the communication hub configuredto communicate with a remote computer via a wireless network.
 33. Theapparatus of claim 23 wherein the sensor module includes a battery toprovide power to the sensor and the communication circuitry.
 34. Theapparatus of claim 23 wherein the sensor module includes a temperaturesensor for detecting temperature; and wherein the communicationcircuitry is operable to communicate data associated with the detectedtemperature to the communication hub.
 35. An apparatus for monitoring aconveyor belt cleaner, the apparatus comprising: a sensor moduleconfigured to be mounted on an elongate support of the conveyor beltcleaner; a clamp portion of the sensor module having an inner surface toengage an outer surface of the elongate support, the clamp portion ofthe sensor module configured to clamp the inner surface of the sensormodule against the outer surface of the elongate support and secure thesensor module to the elongate support so that the sensor module moveswith the elongate support during conveyor belt operation; a sensor ofthe sensor module configured to detect at least one characteristic ofthe elongate support; communication circuitry of the sensor module, thecommunication circuitry configured to communicate data associated withthe at least one characteristic of the elongate support to acommunication hub; wherein the clamp portion of the sensor moduleincludes a sleeve portion having an opening to receive the elongatesupport; and wherein the sleeve portion of the sensor module includes apair of ends separated by a gap, wherein the clamp portion includes aclamping member operable to narrow the gap and secure the sensor moduleon the elongate support.
 36. An apparatus for monitoring a conveyor beltcleaner, the apparatus comprising: a sensor module configured to bemounted on an elongate support of the conveyor belt cleaner; a clampportion of the sensor module having an inner surface to engage an outersurface of the elongate support, the clamp portion of the sensor moduleconfigured to clamp the inner surface of the sensor module against theouter surface of the elongate support and secure the sensor module tothe elongate support so that the sensor module moves with the elongatesupport during conveyor belt operation; a sensor of the sensor moduleconfigured to detect at least one characteristic of the elongatesupport; communication circuitry of the sensor module, the communicationcircuitry configured to communicate data associated with the at leastone characteristic of the elongate support to a communication hub; andwherein the clamp portion of the sensor module includes a C-shapedmember.
 37. An apparatus for monitoring a conveyor belt cleaner, theapparatus comprising: a single, unitary body configured to be mounted toan elongate support of the conveyor belt cleaner; a sensor carried bythe body and configured to detect at least one characteristic of theelongate support; communication circuitry carried by the body, thecommunication circuitry configured to communicate data associated withthe at least one characteristic of the elongate support to an externaldevice; and inner surface portions of the body having an initialconfiguration wherein the inner surface portions permit the elongatesupport to be received therebetween and a clamping configuration whereinthe inner surface portions clamp an outer surface of the elongatesupport therebetween so that the body moves with the elongate supportduring conveyor belt operation.
 38. The apparatus of claim 37 whereinthe body has an opening sized to receive the elongate support; andwherein the inner surface portions of the body extend about the opening.39. The apparatus of claim 37 wherein the body has an opening sized toreceive the elongate support; wherein the body has a gap that opens tothe opening and extends away from the elongate support with the elongatesupport received in the opening; and wherein the inner surface portionsof the body are disposed opposite each other on either side of the gap.40. The apparatus of claim 37 wherein the body has an inner annularsurface; and wherein the inner annular surface of the body comprises theinner surface portions of the body.
 41. The apparatus of claim 37wherein the body has a circular opening to receive the elongate support;and wherein the inner surface portions of the body are diametricallyopposed from one another across the opening for clamping the elongatesupport therebetween in the clamping configuration.
 42. The apparatus ofclaim 37 further comprising a clamping member operable to shift theclamping surface portions from the initial configuration to the clampingconfiguration.
 43. The apparatus of claim 42 wherein the clamping memberincludes a band.
 44. The apparatus of claim 37 further comprising athreaded member and a nut operably connected to the body; and whereintightening the nut and the threaded member together shifts the innersurface portions of the body from the initial configuration to theclamping configuration.
 45. The apparatus of claim 37 wherein the bodyhas a pair of ends separated by a gap; wherein the ends of the body areseparated by a first distance with the clamping surface portions in theinitial configuration; and wherein the ends of the body are separated bya second distance that is less than the first distance with the clampingsurface portions in the clamping configuration.
 46. The apparatus ofclaim 37 in combination with the conveyor belt cleaner having at leastone cleaning blade; the apparatus further comprising a processorconfigured to identify wear of the at least one cleaner blade based atleast in part upon the at least one characteristic of the elongatesupport.
 47. The apparatus of claim 37 further comprising a batteryoperatively connected to the sensor and the communication circuitry. 48.The apparatus of claim 37 further comprising a temperature sensor fordetecting temperature; and wherein the communication circuitry isoperable to communicate data associated with the detected temperature tothe external device.
 49. The apparatus of claim 37 in combination withthe external device, wherein the external device is a communication hubor an apparatus for monitoring another conveyor belt cleaner.
 50. Theapparatus of claim 37 wherein the communication circuitry is configuredto wirelessly communicate the data to the external device.
 51. Anapparatus for monitoring a conveyor belt cleaner, the apparatuscomprising: a body configured to be mounted to an elongate support ofthe conveyor belt cleaner; a sensor carried by the body and configuredto detect at least one characteristic of the elongate support;communication circuitry carried by the body, the communication circuitryconfigured to communicate data associated with the at least onecharacteristic of the elongate support to an external device; and aclamp connected to the body and having an actuator operable to cause theclamp to deform the body and clamp the body to the elongate support. 52.The apparatus of claim 51 wherein the clamp includes a threaded memberand a nut threadingly engaged with the threaded member.
 53. Theapparatus of claim 51 wherein the actuator is rotatable to cause theclamp to deform the body.
 54. The apparatus of claim 51 wherein the bodyhas an inner surface portion to engage the elongate support and an outersurface portion opposite the inner surface; and wherein the clamp has aclamp inner surface portion configured to engage the outer surfaceportion of the body and deform the body.
 55. The apparatus of claim 51wherein the body comprises inner surface portions having an initialconfiguration wherein the inner surface portions permit the elongatesupport to be received therebetween and a clamping configuration whereinthe inner surface portions clamp the elongate support therebetween; andwherein the clamp is operable to shift the inner surface portions fromthe initial configuration to the clamping configuration by deforming thebody.
 56. The apparatus of claim 51 wherein the body includes endsseparated by a gap, the ends facing one another across the gap; andwherein the clamp is operable to narrow the gap by deforming the body.57. The apparatus of claim 51 wherein the clamp includes clamp portionson opposite sides of the body; and wherein the actuator is operativelyconnected to the clamp portions and operable to shift the clamp portionstogether to deform the body.
 58. The apparatus of claim 51 wherein thebody is configured to separate the clamp from the elongate support withthe body mounted to the elongate support.
 59. The apparatus of claim 51wherein the clamp includes a band.
 60. The apparatus of claim 51 incombination with the conveyor belt cleaner; and wherein the at least onecharacteristic includes a position of the elongate support.
 61. Theapparatus of claim 51 in combination with the external device, whereinthe external device is a communication hub or an apparatus formonitoring another conveyor belt cleaner.
 62. The apparatus of claim 51wherein the communication circuitry is configured to wirelesslycommunicate the data to the external device.
 63. The apparatus of claim51 further comprising a faceplate having a user interface.
 64. Theapparatus of claim 51 wherein the elongate support has a length, theapparatus further comprising elongate cylindrical batteries operativelyconnected to the sensor and the communication circuitry to provide powerto the sensor and the communication circuitry; and wherein the elongatecylindrical batteries each have a length oriented to extend parallel tothe length of the elongate support with the body mounted to the elongatesupport.
 65. The apparatus of claim 51 further comprising: a circuitboard; and elongate cylindrical batteries carried by the body andoperatively connected to the sensor and the communication circuitry toprovide power to the sensor and the communication circuitry; and whereinthe elongate cylindrical batteries each have a central axis parallel toa plane of the circuit board.